JPH073604A - Method for producing non-woven fabric and device therefor - Google Patents

Abstract

PURPOSE:To provide a method for producing a non-woven fabric, capable of obtaining the uniform non-woven fabric large in the strength in the longitudinal direction and capable of freely controlling the longitudinal/lateral direction ratio of the strength, and a device therefor. CONSTITUTION:A method for producing a non-woven fabric is characterized by depositing a fiber bundle 20 blown out together with a gas flow from an air sucker 15 on an air-permeable collecting means 30 and disposing an air flow-shutting means 40 on the lower side of the fiber bundle-depositing site A of the collecting means 30 for controlling the gas flow to widely deposit the fiber bundle 20 in the longitudinal direction. The collecting means 30 may be tilted at a specific angle based on the flow direction of the fiber bundle 20 to deposit the fiber bundle 20 more widely in the longitudinal direction.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a nonwoven fabric manufacturing method and apparatus, and can be used for manufacturing a nonwoven fabric having a large strength in the machine direction.

[0002]

2. Description of the Related Art Conventionally, nonwoven fabrics having various properties such as one having a large strength in the longitudinal direction and one having a uniform strength in both the longitudinal and lateral directions have been manufactured depending on the use and the like of the nonwoven fabric. For example, when a non-woven fabric is used in a relatively wide surface state such as a backing material for furniture, a base material for bedding, an agricultural sheet, a material for clothing, etc., a material having uniform strength in both vertical and horizontal directions is used. . On the other hand, when a non-woven fabric is cut into thin pieces and used in a vertically long shape, such as a wire winding material, various kinds of string material, and a top material for paper diapers, a material having a large strength in the vertical direction is used.

Among these, particularly when the continuous processing of the non-woven fabric by the processing machine is performed in the post-processing of the non-woven fabric, for example, in the case of producing a paper diaper, in order to cope with the pulling by the processing machine and the speeding up of the processing machine. In addition, the nonwoven fabric is required to have strength in the longitudinal direction and low elongation. And
In such a case, it is preferable that the strength in the vertical direction can be arbitrarily set so as to be suitable for each post-processing method.

In response to such demands, various methods have been proposed in order to arbitrarily change the ratio of the strength in the longitudinal direction to the strength in the lateral direction or to positively improve the strength in the longitudinal direction. . For example, FIG. 3 shows a so-called spunbond type vertical structure disclosed in JP-A-61-70060, JP-A-61-75863, JP-A-60-39465, and JP-A-59-216963. A method of making a nonwoven having directional strength is shown. In this method, a fiber bundle (filament group) 90, which is formed by a die and then ejected from an upper air sucker or the like along with an air stream and descends in a slump shape, is applied to a flat plate 91, and then the flat plate 91 is formed.
By changing the direction of a part of the fiber bundle 90A by a projection plate 92 provided intermittently in the width direction of 91 and forming a predetermined angle with the flat plate 91, the remaining fiber bundle 90B can be made to follow the flat plate 91. , Separate and run the fiber bundle 90. After separating and running the fiber bundle 90 in this way, if it is deposited on the collection surface, the fiber bundle 90
The pattern drawn by the filaments on the collecting surface is arranged in the longitudinal direction, and the desired strength in the longitudinal direction can be obtained.

[0005]

However, in the above-described manufacturing method of FIG. 3, since the fiber bundles 90 are arranged in the vertical direction and deposited on the collecting surface, the strength in the vertical direction can be obtained, and Although it is possible to adjust the strength ratio in the vertical / horizontal direction by changing the angle formed by the flat plate 91 and the projecting plate 92, the fiber bundle 90A running along the projecting plate 92 and the flat plate 91 running along There is a possibility that the number of filaments with the fiber bundle 90B to be formed may be uneven, or streaky spots may be generated at the portion corresponding to the boundary between the flat plate 91 and the projecting plate 92, and a uniform nonwoven fabric cannot be obtained. However, there was a problem that the appearance was also poor.

The object of the present invention is to provide a large strength in the longitudinal direction,
Another object of the present invention is to provide a method for manufacturing a nonwoven fabric and an apparatus for the same, which can obtain a uniform nonwoven fabric and can freely adjust the strength ratio in the longitudinal / lateral directions.

[0007]

According to the present invention, an air flow shielding means is provided below a collecting means, and a pattern in which filaments in a fiber bundle are drawn on the collecting surface of the collecting means is arranged in a longitudinal direction. By doing so, the above object is achieved. Specifically, in the method for producing a nonwoven fabric of the present invention, a fiber bundle is jetted together with an air stream to be deposited on the collecting surface of a breathable collecting means, and the collecting means is provided on the back side of this stacking position. It is characterized in that the air flow passing therethrough is shielded.
Further, the nonwoven fabric manufacturing method of the present invention is characterized in that the collecting surface of the collecting means is inclined at a predetermined angle with respect to the flow direction of the fiber bundle. Further, the nonwoven fabric manufacturing apparatus of the present invention is provided with an air-permeable collecting means for accumulating the ejected fiber bundles, and an air flow shielding means provided below the portion of the collecting means where the fiber bundles are accumulated. And having. The nonwoven fabric manufacturing apparatus of the present invention is characterized in that the collecting surface of the collecting means is provided so as to be inclined at a predetermined angle with respect to the flow direction of the fiber bundle.

[0008]

According to the present invention as described above, the fiber bundle is ejected from the upper air sucker or the like together with the airflow, and is lowered downward in a scaly form, and the fiber bundle is deposited on the collecting surface of the air-permeable collecting means. To form a web, and send it to each device such as an embossing roll for thermocompression downstream. At this time, the air flow passing through the breathable collecting means from the upper side to the lower side is sucked and collected by the suction box or the like, but the air flow is shielded below the portion of the collecting means where the fiber bundles are accumulated. Since the means is provided, the airflow sent from the upper air sucker or the like flows through both sides of the airflow shielding means (front and rear sides in the moving direction of the collecting means) and is collected by a suction box or the like. Become so. Therefore, the fiber bundles are gradually spread in the vertical direction (moving direction of the collecting means) above the collecting surface of the collecting means, and are arranged and accumulated while drawing a long loop in the vertical direction on the collecting surface. Therefore, a non-woven fabric having a high strength in the machine direction can be obtained. Further, by adjusting the size (length in the vertical direction) and shape of the airflow shielding means or the distance between the airflow shielding means and the collecting means to change the airflow, the fiber bundle can be freely spread in the vertical direction. The strength of the non-woven fabric in the machine direction (strength ratio in the machine / transverse direction) can be set arbitrarily.

Then, the fiber bundle is not forcibly separated on the upper side of the collecting means unlike the flat plate 91 and the projecting plate 92 of the conventional example shown in FIG. 3, but is provided on the lower side of the collecting means. By controlling the air flow by the air flow shielding means, it can be gradually expanded in the longitudinal direction, so a uniform non-woven fabric can be obtained.
The appearance is also good.

Further, if the collecting surface of the collecting means is provided so as to be inclined at a predetermined angle with respect to the flow direction of the fiber bundle, the fiber bundle spreading in the longitudinal direction will hit the collecting surface diagonally.
Furthermore, the lengthwise arrangement on the collection surface becomes longer, increasing the strength of the nonwoven fabric in the lengthwise direction, and changing the inclination angle allows the strength of the nonwoven fabric in the lengthwise direction to be set arbitrarily. Therefore, the above-mentioned object is achieved.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 shows the overall configuration of a nonwoven fabric manufacturing apparatus 10 according to this embodiment. The non-woven fabric manufacturing apparatus 10 is a so-called spunbond type non-woven fabric manufacturing apparatus, and includes an extruder 11 for extruding the raw material of the non-woven fabric supplied from a hopper or the like (not shown), and a gear pump 12 for sending the raw material extruded from the extruder 11 to the downstream. A die 13 for forming a fiber bundle 20 of continuous fibers, and a cooling chamber 14 for cooling the fiber bundle 20.
And an air sucker 15 for ejecting gas and pulling the fiber bundle 20 downward. Then, on the downstream side of the air sucker 15, a suction conveyor 30 that is a collecting means that deposits the fiber bundle 20 to form the web 21, a conveyor 17 that conveys the web 21, and an embossing roll that thermocompresses the web 21.
18 and.

The die 13 has a large number of holes vertically and horizontally arranged on the lower surface thereof, and these holes are used as spinning nozzles for spinning a molten raw material to form a fiber bundle 20 of continuous fibers. ing. Air Soccer 15 is the upper die 13
The fiber bundles 20 formed by the above are arranged in a substantially horizontal row by the rectangular slits 16, and a high-speed air stream is ejected to send the fiber bundles 20 to the suction conveyor 30 below.

The suction conveyor 30 is composed of a breathable moving belt 35 having a mesh, a plurality of rolls 36 for supporting or driving the moving belt 35, and the like. The collecting surface 31 forms the web 21 by accumulating the fiber bundles 20 coming down from the. Below the position where the fiber bundle 20 of the suction conveyor 30 is deposited (point A in the figure), a suction box is installed.
32 are provided. The suction box 32 collects the high-speed air current for towing the fiber bundle 20 ejected from the air sucker 15, and sucks gas from the suction blower 33 connected to the suction box 32 to discharge it to the outside. It has become.

Between the position A where the fiber bundle 20 is deposited on the suction conveyor 30 and the suction box 32, there is provided a cylindrical blind roll 40 as an air flow shielding means. FIG. 2 is an enlarged view of the blind roll 40 and its vicinity. The blind roll 40 is provided so as to contact the back surface of the collection surface 31 of the suction conveyor 30 and support the moving belt 35, and its axial direction is a lateral direction (a direction perpendicular to the moving direction of the moving belt 35). Has become. Blind roll
The diameter D of 40 is the fiber bundle 20 coming down from the air soccer 15.
When the sheet spreads in the vertical direction (moving direction of the moving belt 35) in the vicinity of the position A on the collecting surface 31, the landing surface width H is appropriately adjusted to be a desired width. Here, the larger the diameter D of the blind roll 40, the more the fiber bundle 20 spreads in the vertical direction and the larger the landing surface width H, so that sufficient strength in the vertical direction can be obtained.

Further, in the vicinity of the position A where the fiber bundle 20 contacts the collecting surface 31, the moving belt 35 of the suction conveyor 30 is provided.
Is an ascending slope that makes a predetermined inclination angle α with respect to the horizontal plane. That is, the moving belt 35 is a fiber bundle.
It is provided at a predetermined angle (90 degrees-α) with respect to the flow direction of 20. Here, the larger the inclination angle α, the more the fiber bundle
20 spreads in the vertical direction to increase the landing surface width H, and sufficient strength in the vertical direction can be obtained.

The embossing roll 18 is a device for thermocompression-bonding the web 21 sent by the conveyer 17, and is provided with two rolls at the top and bottom, and one roll is provided with an embossed face having many projections. A smooth surface is formed on the other roll, and the web 21 is sandwiched between these rolls to form a nonwoven fabric as a product.

In this embodiment, the nonwoven fabric is manufactured as follows. First, the raw material of the non-woven fabric is supplied from the extruder 11 to the die 13 through the gear pump 12,
A fiber bundle 20 of continuous fibers is formed by 13, the fiber bundle 20 is cooled in a cooling chamber 14, and then sent through a slit 16 of an air sucker 15 to a suction conveyor 30 below together with a high-speed air stream.

Next, the fiber bundle 20 ejected from the air sucker 15 is deposited on the collecting surface 31 of the moving belt 35 while drawing a loop, thereby forming the web 21. At this time, the fiber bundle 20
Is the collecting surface 31 due to the airflow shielding effect of the blind roll 40.
Gradually spreads in the vertical direction as the distance becomes closer to, and becomes the landing surface width H on the collecting surface 31. Then, the web 21 on the collecting surface 31 is sent by the moving belt 35 to the downstream transport conveyor 17. On the other hand, the high-speed airflow that pulls the fiber bundle 20 is collected by the suction box 32 through the mesh of the moving belt 35 of the suction conveyor 30 and discharged from the suction blower 33 to the outside. At this time, the air flow is a blind roll as shown by arrow B in the figure.
Pass both sides of blind roll 40 avoiding 40.

After that, the web 21 is sent to the embossing roll 18 by the conveyer 17, and the non-woven fabric is formed by thermocompressing the web 21 with the embossing roll 18, and the non-woven fabric is formed by a winding machine (not shown) provided downstream of the embossing roll 18. Is rolled up into a product.

According to this embodiment, the following effects are obtained. That is, the fiber bundle of the suction conveyor 30
Since the blind roll 40 is provided between the position A where the 20 is accumulated and the suction box 32, a part of the airflow after passing the moving belt 35 can be shielded. Therefore, the airflow after passing through the moving belt 35 flows so as to spread in the vertical direction while avoiding the blind roll 40, so that the fiber bundle ejected from the air sucker 30 together with the airflow.
20 can be expanded in the longitudinal direction, and a nonwoven fabric having high strength in the longitudinal direction can be obtained.

Further, in the vicinity of the position A where the fiber bundle 20 contacts the collecting surface 31, the moving belt 35 of the suction conveyor 30 is provided.
Since a predetermined inclination angle α with respect to the horizontal plane, it is possible to obliquely spread the fiber bundle 20 spread in the vertical direction on the collection surface 31, so that the fiber bundle 20 is more vertically aligned. It is possible to obtain a non-woven fabric having a large longitudinal strength. Since the inclination angle α is an upward inclination, the amount of air flow that is blown away and is not collected can be reduced, and the suction capacity of the suction box 32 can be reduced, as compared to the case where the inclination angle α is a downward inclination. .

Further, the fiber bundle 20 is not forcibly separated above the suction conveyor 30 unlike the flat plate 91 and the projecting plate 92 of the conventional example shown in FIG. 3, but the air flow is controlled by the blind roll 40. Since it can be gradually expanded in the longitudinal direction, a uniform non-woven fabric can be obtained and the appearance can be improved.

Further, by changing the diameter D of the blind roll 40 and the inclination angle α of the suction conveyor 30,
The longitudinal spread of the fiber bundle 20 can be freely adjusted, and the strength of the nonwoven fabric in the longitudinal direction, in other words, the strength ratio in the longitudinal / lateral direction can be arbitrarily set.

Furthermore, the fiber bundle 20 can be expanded in the longitudinal direction only by providing the blind roll 40 having a simple structure at a position for blocking the air flow after passing through the moving belt 35 of the suction conveyor 30. Conventional plate 91 shown
Also, the facility cost can be reduced without requiring a complicated facility or device such as the projecting plate 92.

The following comparative experiments were conducted to confirm the effect of the present invention. Polypropylene (Idemitsu Polypro Y6005G) was used as a raw material, and a non-woven fabric having a basis weight of 20 g / m ² was produced by setting various conditions in the non-woven fabric producing apparatus 10 described above. As an experimental example of the embodiment, the blind roll 40
Diameter D (mm) of 60, 90, 120, 150, 180 mm and tilt angle α of 0, 20, 25, 30 degrees (uphill) and -25 degrees (downhill) for a total of 12 conditions. Set. On the other hand, as a comparative example, in the absence of the blind roll 40, the inclination angle α was changed at 0, 20, 25, 30 degrees (upward inclination) and -25 degrees (downward inclination), and a total of 5 types of conditions were set. .

The moving belt of the suction conveyor 30
35 is made of plastic and its air permeability is 330 cc / cm ² / s
The one from ec was used. Then, the quality (physical properties, degree of fiber arrangement, appearance) of the nonwoven fabric obtained under each condition is evaluated, and the fiber bundle 20 on the collection surface 31 of the suction conveyor 30 is evaluated.
The moldability was also evaluated based on the blown-off condition. The physical properties are JIS
The tensile strengths in the longitudinal and transverse directions were measured based on the L1096 method, and the values were shown as the load value (kg / 5cm) when the amount of deformation of the nonwoven fabric due to pulling reached 10%. The degree of fiber arrangement is shown by the ratio of the load value in the vertical direction to the horizontal direction. As for the appearance, the uniformity of the nonwoven fabric after production (whether or not unevenness, vertical streaks, thread clumps, etc.) was visually evaluated.

[0027]

[Table 1]

Table 1 shows the results of the comparative experiment. Comparing Experimental Examples 1 to 5 with Comparative Example 1, the inclination angle α
At 0 °, in Experimental Examples 1 to 5 in which the blind roll 40 is provided, the strength in the longitudinal direction and the longitudinal / horizontal ratio of the strength are larger than those in Comparative Example 1. In addition, Experimental Examples 1 to
5, the larger the diameter D of the blind roll 40, the larger the longitudinal strength and the aspect ratio of the strength. By changing the diameter D of the blind roll 40, the longitudinal strength and the longitudinal strength of the longitudinal direction are increased. It has been shown that the / aspect ratio can be adjusted. In Experimental Examples 4 and 5, vertical streaks are generated, and it can be seen that when the diameter D of the blind roll 40 is too large, the strength in the vertical direction can be sufficiently obtained, but the appearance is deteriorated.

Further, Experimental Examples 6 to 8 and 9 to 11 and Comparative Example 2
4 to 9, the experimental examples 6 to 8 and 9 to 11 in which the blind roll 40 is provided have the same longitudinal strength and longitudinal strength as compared to Comparative examples 2 to 4 at the same inclination angle α.
The aspect ratio is large. In addition, Experimental Examples 6 to 8 and 9 to 1
Under the condition that the diameter D of the blind roll 40 is the same in No. 1, as the inclination angle α is larger, the strength in the longitudinal direction and the aspect ratio of the strength are larger, and the strength in the longitudinal direction is changed by changing the inclination angle α. And that the aspect ratio of strength can be adjusted.

Further, in Experimental Example 12, the inclination angle α is a downward inclination in the state where the blind roll 40 is provided, but as compared with Experimental Example 9, the longitudinal strength and the longitudinal strength having the same degree of strength are obtained. / Aspect ratio is obtained, and the moldability and appearance are also good results. On the other hand, Experimental Example 12 and Comparative Example 5
Comparing with, even in the case where the inclination angle α is a downward inclination, the experimental example 12 provided with the blind roll 40 has a larger strength in the longitudinal direction and the longitudinal aspect ratio of the strength than the comparative example 5. However, it is shown that if the blind roll 40 is provided, it is possible to manufacture a nonwoven fabric having a sufficient function even when the slope is downhill. And Experimental Examples 1 to 1
In No. 2, except for Experimental Examples 4 and 5 in which the diameter D of the blind roll 40 was considerably increased, the moldability and the appearance were both good. From the results of the above comparative experiments, it can be seen that the effects of the present invention are remarkably exhibited.

The present invention is not limited to the above-described embodiments, but includes other configurations that can achieve the object of the present invention, and the following modifications and the like are also included in the present invention. That is, in the above-described embodiment, the high-speed airflow is jetted by the air sucker 15 having the rectangular slit 16 to pull the fiber bundle 20 downward, but the present invention is not limited to such a type of air sucker 15, and in short Any device capable of pulling the fiber bundle 20 downward may be used. Also, the extruder 11,
The configurations of the gear pump 12, the die 13, the cooling chamber 14, the conveyer 17, the embossing roll 18 and the like are not limited to the configurations of the above-described embodiment, and may be any configurations, that is, as long as a spunbond type nonwoven fabric manufacturing apparatus can be configured.

Further, although the suction conveyor 30 has the upward inclination angle α in the above embodiment, it may have the downward inclination angle α or may be horizontal.
However, it is desirable to set the upward inclination angle α,
By doing so, the fiber bundle 20 can be expanded in the vertical direction, and the airflow can be reduced.
Further, in the embodiment, the collection surface 31 of the suction conveyor 30 is inclined with respect to the horizontal plane, but the collection surface 31 is horizontal and the fiber bundle 20 ejected together with the airflow from the air sucker 15 is the Coanda effect or the like. May be used to incline, or the air sucker 15 itself may be inclined, that is, the fiber bundle 20 may be obliquely attached to the collection surface 31 and deposited.

The suction conveyor 30 can be made of any material such as plastic or stainless steel, and it is sufficient that it has sufficient air permeability and has a function of accumulating and transporting the fiber bundle 20. . Further, in the above embodiment, the collecting means is a breathable moving belt having a mesh.
Although it is the suction conveyor 30 configured by 35 and a plurality of rolls 36, it is not limited to such a belt type configuration, for example, may be configured by using a hollow rotating cylinder having perforation, In this case, the blind roll 40 may be provided inside the hollow rotating cylinder.

Further, in the above-mentioned embodiment, the air flow shielding means is the blind roll 40 having a cylindrical shape, but the shape is arbitrary, and for example, it may be a mere plate-shaped shield or a cross section. The shape may be an elliptical shape, a triangular shape, a trapezoidal shape, or a V shape. In short, the airflow after being long in the lateral direction (the width direction of the nonwoven fabric) and passing through the moving belt 35 of the suction conveyor 30. Any material can be used as long as it can shield a part of it.

In the above embodiment, the blind roll is used.
40 is a collecting surface 31 of the moving belt 35 of the suction conveyor 30.
While supporting the moving belt 35 by contacting the back surface of the moving belt 35, it may be separated from the moving belt 35. In that case, the fiber bundle 20
It is only necessary to install other supporting rolls or the like on both sides of the position A at which the surface is collected on the collecting surface 31. Then, by changing the distance between the blind roll 40 and the moving belt 35, the strength of the nonwoven fabric in the longitudinal direction (strength ratio in the longitudinal / lateral direction) can be arbitrarily adjusted. Here, the closer these distances are to each other, the more the fiber bundle 20 spreads in the vertical direction and the larger the landing surface width H becomes, so that sufficient strength in the vertical direction can be obtained. further,
The blind roll 40 may rotate with the movement of the moving belt 35, or may be fixed.

The raw material of the non-woven fabric is arbitrary as long as it can be applied to the spunbond type manufacturing method, and for example, thermoplastic resin such as polypropylene, polyethylene terephthalate, polyamide (nylon) and the like can be applied. .

[0037]

As described above, according to the present invention, since the airflow shielding means is provided below the collecting means to control the airflow for pulling the fiber bundle, the filaments in the fiber bundle are collected by the collecting means. The pattern drawn on the collecting surface can be spread in the longitudinal direction and arranged, and a non-woven fabric having a large strength in the longitudinal direction and uniform can be obtained, and the strength ratio in the longitudinal / lateral direction can be arbitrarily adjusted. The effect is that you can.

[Brief description of drawings]

FIG. 1 is an overall perspective view showing an embodiment of the present invention.

FIG. 2 is an enlarged view showing a main part of the embodiment.

FIG. 3 is a perspective view showing a conventional example.

[Explanation of symbols]

 10 Non-woven fabric manufacturing device 13 Die 15 Air sucker 20 Fiber bundle 21 Web 30 Suction conveyor 31 which is a collection means 31 Collection surface 32 Suction box 35 Moving belt 40 Blind roll α which is an air flow blocking means α The inclination of the collection surface of the collection means angle

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Tadahiro Matsumoto 417-1 Sakuda, Kujukuri-cho, Sanmu-gun, Chiba Inside Uni Chemical Co., Ltd.

Claims (4)

[Claims] 1. A fiber bundle is ejected together with an air flow to be deposited on a collection surface of a gas permeable collection means, and the air flow passing through the collection means is shielded on the back side of the deposition position. A method for producing a characteristic nonwoven fabric. 2. The method for producing a non-woven fabric according to claim 1, wherein the collection surface of the collection means is inclined at a predetermined angle with respect to the flow direction of the fiber bundle. 3. An air-permeable collecting means for accumulating the ejected fiber bundles, and an air flow shielding means provided below the portion of the collecting means where the fiber bundles are accumulated. Non-woven fabric manufacturing equipment. 4. The non-woven fabric manufacturing apparatus according to claim 3, wherein the collecting surface of the collecting means is provided at a predetermined angle with respect to the flow direction of the fiber bundle. Non-woven fabric manufacturing equipment.