US20140186538A1

US20140186538A1 - Method and apparatus for manufacturing cleaning member

Info

Publication number: US20140186538A1
Application number: US13/749,723
Authority: US
Inventors: Hiroaki Goto; Yasuhiro Koyama
Original assignee: Unicharm Corp
Current assignee: Unicharm Corp
Priority date: 2012-12-29
Filing date: 2013-01-25
Publication date: 2014-07-03
Also published as: JP5808315B2; WO2014104321A1; JP2014128503A

Abstract

The present invention provides a novel method and apparatus for manufacturing a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity, wherein a first fiber bundle fed continuously in a prescribed direction is brought into contact with a transfer roller rotated in a direction opposite to the feeding direction of the first fiber bundle to transfer the oil agent applied to the surface of the transfer roller to the first fiber bundle.

Description

TECHNICAL FIELD

The present invention relates to a method and apparatus for manufacturing a cleaning member including a fiber bundle with an oil agent attached thereto.

BACKGROUND ART

In a cleaning member including a fiber bundle as a substrate, a fiber bundle having an oil agent attached thereto is utilized in order to improve dust collecting capability of the fiber bundle (see, for example, Patent Literature 1).
On the other hand, as a method for attaching an oil agent to a fiber bundle, a method has been known in which a transfer roller rolling in the same direction as the feeding direction of the fiber bundle is brought into contact with the fiber bundle so as to transfer an oil agent applied on the surface of the transfer roller to the fiber bundle (see, for example, Patent Literature 2). Also, a method has been known in which, in order to bring a fiber bundle into adequately close contact with a transfer roller, a backup roller provided on the side of the fiber bundle opposite to the transfer roller is used to press the fiber bundle to the transfer roller (see, for example, Patent Literature 1).

CITATION LIST

Patent Literature

[PTL 1] Japanese Unexamined Patent Publication No. H05-245090
[PTL 2] Japanese Unexamined Patent Publication No. H11-323718

SUMMARY OF INVENTION

Technical Problem

However, when the transfer roller rotating in the same direction as the feeding direction of the fiber bundle is brought into contact with the fiber bundle, it is difficult to attach the oil agent uniformly to the fiber bundle with no irregularity. On the other hand, when the backup roller is used to press the fiber bundle to the transfer roller, the fiber bundle may be wound around the backup roller and may give rise to trouble in feeding of the fiber bundle.
Therefore, it is an object of the present invention to provide a novel method and apparatus for manufacturing a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity.

Solution to Problem

In order to solve the above-described problem, the present invention provides a method for manufacturing a cleaning member including a fiber bundle having an oil agent attached thereto, the method comprising a step of bringing the fiber bundle continuously fed in a prescribed direction into contact with a roller rotated in a direction opposite to the feeding direction of the fiber bundle so as to transfer the oil agent applied on the surface of the roller to the fiber bundle.
The present invention also provides an apparatus for manufacturing a cleaning member including a fiber bundle having an oil agent attached thereto, the apparatus comprising a fiber bundle feeding unit that feeds the fiber bundle in a prescribed direction, a roller provided so as to come into contact with the fiber bundle while being rotated in a direction opposite to the feeding direction of the fiber bundle, and an oil agent application unit that applies the oil agent to the surface of the roller before the roller comes into contact with the fiber bundle.
In the method and apparatus of the present invention, “a direction opposite to the feeding direction of the fiber bundle” means that the direction of the tangential velocity of the portion of the roller in contact with the fiber bundle is opposite to the feeding direction of the fiber bundle.

Effect of Invention

According to the present invention, it is possible to provide a novel method and apparatus for manufacturing a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view showing a cleaning member manufactured according to an embodiment of the method and apparatus of the present invention, and a holder to be fixed to the cleaning member;

FIG. 2 is a cross-sectional view taken along the line X-X of FIG. 1;

FIG. 3 is a plan view showing the cleaning member shown in FIG. 1;

FIG. 4 is a schematic view useful for explaining the method and apparatus for manufacturing the cleaning member shown in FIG. 1; and

FIG. 5 is a cross-sectional view useful for explaining another embodiment of the method and apparatus for manufacturing the cleaning member shown in FIG. 1.

DESCRIPTION OF EMBODIMENTS

The present invention will be described in detail below.
A method according to aspect 1A of the present invention is a method for manufacturing a cleaning member including a fiber bundle having an oil agent attached thereto, comprising a step of bringing the fiber bundle continuously fed in a prescribed direction into contact with a roller rotated in a direction opposite to the feeding direction of the fiber bundle so as to transfer the oil agent applied on the surface of the roller to the fiber bundle. By using the roller rotated in a direction opposite to the feeding direction of the fiber bundle, the oil agent is accumulated between the fiber bundle and the roller at a position upstream of the contact point of the fiber bundle and the roller in the rotating direction of the roller, so that the oil agent can be attached uniformly to the fiber bundle with no irregularity. Thus, in accordance with the method according to aspect 1A, it is possible to manufacture a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity.
In the method according to aspect 1A, the fiber bundle is preferably brought into contact with the roller while the fiber bundle is held in a floating state (aspect 2A). The term “floating state” means that, when a force is exerted to the fiber bundle, the fiber bundle is free to be moved in any direction of the exerted force (for example, upward, downward, to the left or to the right). For example, if, at the time of contact of the fiber bundle with the roller, upward pressing force is exerted to the fiber bundle by the roller, the fiber bundle is free to be moved in upward direction, and when the force is released, it is free to be moved downward direction. In the method according to aspect 2A, by holding the fiber bundle in floating state and bringing the fiber bundle into contact with the roller being rotated in the direction opposite to the feeding direction of the fiber bundle, the oil agent can be attached uniformly to the fiber bundle with no irregularity, and unlike the case where a backup roller is used to press the fiber bundle against the roller, there is no risk of the fiber bundle being wound around the backup roller and giving rise to trouble to smooth feeding of the fiber bundle. Thus, in accordance with the method according to aspect 2A, it is possible to efficiently manufacture a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity.
In the method according to aspect 1A or 2A, the roller is preferably a mirror surface roller (aspect 3A). In accordance with the method according to aspect 3A, the fiber bundle can be prevented from being wound around the roller, so that it is possible to efficiently manufacture a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity.
The method according to any one of aspects 1A to 3A preferably further comprises a step of applying the oil agent to the surface of the roller before bringing the fiber bundle into contact with the roller (aspect 4A).
In the method according to aspect 4A, the oil agent is preferably applied to the roller by rotating the roller with a portion thereof dipped in a bath containing the oil agent (aspect 5A).
The method according to aspect 4A or 5A preferably further comprises a step of achieving a uniform thickness of the oil agent applied on the surface of the roller before bringing the fiber bundle into contact with the roller and after applying the oil agent to the surface of the roller (aspect 6A).
The method according to any one of aspects 1A to 6A may comprise other steps. Other steps may be suitably selected in accordance with the constructions of a cleaning member to be manufactured. Other steps may include, for example, a step of opening the fiber bundle, a step of forming a multilayer web by stacking the opened fiber bundle on one or more other members (for example, a belt-shaped non-woven fabric, etc.), a step of fixing (for example, heat sealing, ultrasonic sealing) the fiber bundle and other members included in the multilayer web, a step of cutting out individual cleaning members from the multilayer web, and the like. The method according to any one of aspects 1A to 6A may comprises one, two or more of these steps. In this case, a step of transferring the oil agent to the fiber bundle may be performed in any time point as long as manufacture of a cleaning member is not impeded. For example, when the method according to any one of aspects 1A to 6A comprises a step of opening the fiber bundle, a step of transferring the oil agent to the fiber bundle may be performed during or after the step of opening the fiber bundle.
An apparatus according to aspect 1B of the present invention is an apparatus for manufacturing a cleaning member including a fiber bundle having an oil agent attached thereto, comprising a fiber bundle feeding unit that feeds the fiber bundle in a prescribed direction, a roller provided so as to come into contact with the fiber bundle while being rotated in a direction opposite to the feeding direction of the fiber bundle, and an oil agent application unit that applies the oil agent to the surface of the roller before the roller comes into contact with the fiber bundle. By using the roller rotated in the direction opposite to the feeding direction of the fiber bundle, the oil agent is accumulated between the fiber bundle and the roller at a position upstream of the contact point of the fiber bundle and the roller in the rotating direction of the roller, so that the oil agent can be attached uniformly to the fiber bundle with no irregularity. Therefore, with the apparatus according to aspect 1B, it is possible to manufacture a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity.
In the apparatus according to aspect 1B, preferably, any member which presses the fiber bundle to the roller is not provided (aspect 2B). In the apparatus according to aspect 2B, since any member which presses the fiber bundle to the roller is not provided, the fiber bundle held in floating state is brought into contact with the roller rotating in the direction opposite to the feeding direction of the fiber bundle, so that the oil agent can be attached uniformly to the fiber bundle with no irregularity, and unlike the case where a backup roller is used to press the fiber bundle against the roller, there is no risk of the fiber bundle being wound around the backup roller and giving rise to trouble to smooth feeding of the fiber bundle. Thus, with the apparatus according to aspect 2B, it is possible to efficiently manufacture a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity.
In the apparatus according to aspect 1B or 2B, the roller is preferably a mirror surface roller (aspect 3B). With the apparatus according to aspect 3B, it is possible to efficiently manufacture a cleaning member including a fiber bundle having an oil agent uniformly attached thereto with no irregularity.
In the apparatus according to any one of aspects 1B to 3B, the oil agent application unit preferably applies the oil agent to the surface of the roller by rotating the roller with a portion thereof dipped in an oil agent bath (aspect 4B).
The apparatus according to any one of aspects 1B to 4B preferably further comprises a blade member which scraps off an excess of the oil agent applied to the surface of the roller before bringing the fiber bundle into contact with the roller and after applying the oil agent to the surface of the roller (aspect 5B).
The apparatus according to any one of aspects 1B to 4B preferably further comprises a roll provided at a constant clearance to the roller so as to achieve a uniform thickness of the oil agent applied to the surface of the roller before bringing the fiber bundle into contact with the roller and after applying the oil agent to the surface of the roller (aspect 6B).
The apparatus according to any one of aspects 1B to 6B may comprises other constructs. Other constructs can be selected suitably in accordance with the constructions of a cleaning member to be manufactured. Other constructs may include, for example, an opening unit which opens the fiber bundle, a formation unit which forms a multilayer web by stacking the opened fiber bundle on one, two or more members (for example, a belt-shaped non-woven fabric, etc.), a fixing unit (for example, heat sealing unit, ultrasonic sealing unit, etc.) which fixes the fiber bundle to other members included in the multilayer web, and a cut-out unit which cuts out individual cleaning members from the multilayer web. The apparatus according to aspects 1B to 6B may include one, two or more of these constructs.
A cleaning member to be manufactured by the method and apparatus of the present invention is not particularly limited as long as it includes a fiber bundle having an oil agent attached thereto. As a cleaning member to be manufactured by the method and apparatus of the present invention, a cleaning member 1 shown in FIGS. 1 to 3, for example, may be mentioned.
Taking the case of manufacturing the cleaning member 1 as an example, an embodiment of the method and apparatus of the present invention will be described below.
First, based on FIGS. 1 to 3, the cleaning member 1 will be described.
FIG. 1 is a perspective view showing the cleaning member 1 and a holder 15 fixed to the cleaning member 1, FIG. 2 is a cross-sectional view taken along the line X-X in FIG. 1, and FIG. 3 is a plan view showing the cleaning member 1 shown in FIG. 1. In the description that follows, although “TOP” and “BOTTOM” in FIG. 2 may be sometimes taken as upper side and lower side, respectively, “TOP” and “BOTTOM” in FIG. 2 are used simply for convenience of explanation, and do not limit upper and lower directions of the cleaning member 1.
As shown in FIGS. 1 to 3, the cleaning member 1 comprises a brush part 2, a substrate sheet 12 stacked on the brush part 2, and a holding sheet 13 stacked on the substrate sheet 12.
As shown in FIGS. 1 to 3, the cleaning member 1 has receiving parts 14 formed to receive an insertion part 16 of the holder 15 between the substrate sheet 12 and the holding sheet 13. As shown in FIGS. 1 to 3, the cleaning member 1 has two receiving parts 14 formed in order to permit the insertion part 16 having two branches. Although the number of receiving parts 14 is two in the present embodiment, the number of receiving parts 14 may be suitably modified depending on the number of branches of the insertion part 16. In another embodiment, the number of receiving parts 14 may be three or more.
As shown in FIG. 2, the brush part 2 comprises four layers of fibrous members consisting of a first fibrous member 3, a second fibrous member 4 stacked on the lower side of the first fibrous member 3, a third fibrous member 5 stacked on the lower side of the second fibrous member 4, and a fourth fibrous member 6 stacked on the lower side of the third fibrous member 5, and a sheet with slits 7 stacked on the lower side of the four layers of the fibrous members (on the lower side of the fourth fibrous member 6). Although the fibrous members of the brush part 2 of the present embodiment have four-layered structure, layered structure of the fibrous members may be suitably modified. In another embodiment, the layered structure of the fibrous members may be monolayered structure, two-layered structure, or three-layered structure. In still another embodiment, the layered structure of the fibrous members may be a structure constructed of five or more layers. Although the brush part 2 of the present embodiment comprises the sheet with slits 7, the presence or absence of the sheet with slits 7 may be suitably chosen. Thus, in another embodiment, the sheet with slits 7 may be omitted.
The first to the fourth fibrous members 3 to 6 are fiber bundles having an oil agent attached thereto. The oil agent in the present embodiment is a dust-collecting oil agent (such as an oil agent containing liquid paraffin as a main component) that exhibits promoting an effect of adsorbing dust and dirt. The amount of the oil agent per cleaning member is usually 0.05 to 2 g/piece, preferably 0.1 to 1 g/piece, more preferably 0.2 to 0.5 g/piece. If the amount of the oil agent is less than 0.05 g/piece, capability for holding dust and dirt may be lowered, and if the amount exceeds 2 g/piece, the oil agent may adhere to an object to be cleaned (for example, furniture and the like). Components of the dust collecting oil agent are not particularly limited, and include mineral oils, synthetic oils, silicone oils, surface active agents and the like. Mineral oils may be paraffinic hydrocarbons, naphthenic hydrocarbons, aromatic hydrocarbons, etc. Synthetic oils may be, for example, alkyl benzene oils, polyolefin oils, polyglycol oils, etc. Silicone oils may be, for example, chain dimethyl polysiloxane, ring dimethyl polysiloxane, methyl hydrodiene polysiloxane, various modified silicones, etc. Surface active agents may be, for example, cationic surface active agents such as quaternary ammonium salt type surfactant, non-ionic surface active agents such as polyethylene glycol type surfactants, polyalcohol type surfactants, etc.
If the dust collecting oil agent is an oil agent having liquid paraffin as a main component, viscosity of the oil agent is preferably in the range of 108 to 128 mm²/S. This viscosity is the viscosity as measured by Ubbelohde method (30° C.) carried out using an Ubbelohde viscometer (defined in JIS K 2839-1980 with coefficient determined in SIS B-0017), a thermometer (as defined in JIS B7410-1982 for dynamic viscosity measurement) and a thermostat (as defined in JIS K2283-1983).
The fiber bundle may be, for example, TOW, preferably opened TOW. The term “TOW” means a bundle of a large number of filaments as described in JIS L 0204-3:1998 3.1.24.
The fiber bundle may be a bundle of slit fibers (fibers formed by cutting a film in elongated form and extending them), split fibers (fibers formed by splitting an elongated film into network segments), or the like.
As the fiber bundle, a fiber bundle composed of thermoplastic fiber, fiber bundle containing thermoplastic fiber, etc., may be mentioned. Raw material of the fiber forming the fiber bundle may be, for example, polyethylene, polypropylene, polyethylene terephthalate, nylon, rayon, etc. Type of the fiber forming the fiber bundle may be, for example, single fiber, composite fiber (for example, core-sheath type composite fiber, side-by-side type composite fiber). Preferably, in view of thermal bondability, composite fiber is core-sheath type composite fiber with melting point of core higher than melting point of sheath.
As preferred core-sheath type composite fiber, core-sheath type composite fiber with core composed of polypropylene or polyethylene terephthalate and sheath composed of polyethylene may be mentioned.
Fineness of the fiber forming the fiber bundle is preferably 1 to 50 dtex, and more preferably 2 to 10 dtex. The fiber bundle may contain plural types of fiber having same fineness, or may contain single or plural types of fiber having different fineness.
In the present embodiment, each fiber composing the fiber bundle is formed as crimped fiber. By forming each fiber as crimped fiber, the fiber bundle can be constructed in bulky form, and can have structure suitable for adsorbing dust and dirt in the crimped portion. In other embodiment, each fiber composing the fiber bundle may be formed as non-crimped fiber.
As will be described later, the sheet with slits 7 is formed of non-woven fabric consisting of thermoplastic fibers (thermally bondable fibers) or non-woven fabric containing thermoplastic fibers, just like the substrate sheet 12 and the holding sheet 13, and is formed in rectangular shape of generally same width and generally same length as the substrate sheet 12. The sheet with slits 7 is provided with incisions (not shown) in the shape of saw tooth at a prescribed separation over the entire length of the sheet with slits 7. With these incisions, reed-shaped parts having the shape of saw tooth on both edges along the entire length at both edges in width direction of the sheet with slits 7 are formed (not shown).
As shown in FIGS. 1 to 3, the substrate sheet 12 and the holding sheet 13 are stacked in this order on the upper side of the first fibrous member 3 of the brush part 2, and the receiving part 14 which receives the insertion part 16 of the holder 15 is formed between the substrate sheet 12 and the holding sheet 13.
As shown in FIG. 3, the substrate sheet 12 and the holding sheet 13 have both rectangular shapes, such that both sheets 12, 13 are set so as to have same dimension in width direction (left-right direction in FIG. 3), and dimension in length direction (up-down direction in FIG. 3) of the substrate sheet 12 is set to be larger than the holding sheet 13, and the holding sheet 13 is stacked on the substrate sheet 12 such that both longitudinal ends of the substrate sheet 12 project outward by a prescribed length from both longitudinal ends of the holding sheet 13.
The substrate sheet 12 and the holding sheet 13 are formed of non-woven fabric composed of thermoplastic fiber (heat adhesive fiber) or non-woven fabric containing thermoplastic fiber. As the thermoplastic fiber, for example, polyethylene fiber, polyethylene terephthalate fiber, composite fiber composed of polyethylene fiber and polyethylene terephthalate fiber, composite fiber composed of polyethylene fiber and polypropylene fiber, and core-sheath type composite fiber with the core composed of polyethylene terephthalate and the sheath composed of polyethylene, for example, may be mentioned. Type of the non-woven fabric may be, for example, thermal bond non-woven fabric, spunbonded non-woven fabric, spunlace non-woven fabric, etc.
In other embodiment, the substrate sheet and the holding sheet are formed of thermoplastic resin film, for example, polyethylene film, polypropylene film. In still other embodiment, the substrate sheet and the holding sheet are formed of laminate sheet of non-woven fabric and resin film.
The substrate sheet 12 and the holding sheet 13 are melt bonded in one unit to all layers of the brush part 2 (the first fibrous member 3, the second fibrous member 4, the third fibrous member 5, the fourth fibrous member 6, and the sheet with slits 7) by a first melt bonded part forming device 158 to be described later, and as shown in FIGS. 1 to 3, in the cleaning member 1, a first melt bonded part 8 extending in longitudinal direction is formed in center portion in width direction. Further, the substrate sheet 12 and the holding sheet 13 are melt bonded on both sides (on the left and the right) of the first melt bonded part 8 to one layer (the first fibrous member 3) by a second melt bonded part forming device 134, and two second melt bonded parts 11 are formed in longitudinal direction in the cleaning member 1. Two second melt bonded parts 11 are intermittently formed, respectively. By fusion of the first fibrous member 3 to the substrate sheet 12 and the holding sheet 13, the first fibrous member 3 follows the movement of these sheets 12, 13, so that the brush part 2 is more easily expanded at the time of usage, and cleaning efficiency can be thereby improved.
The substrate sheet 12 and the holding sheet 13 are melt bonded to all layers of the brush part 2 (the first fibrous member 3, the second fibrous member 4, the third fibrous member 5, the fourth fibrous member 6, and the sheet with slits 7) at the first melt bonded part 8, and are further melt bonded to the first fibrous member 3 of the brush part 2 at the two second melt bonded parts 11. Thus, a pair of receiving parts 14 is formed between the substrate sheet 12 and the holding sheet 13 as a bag-shaped space that is delimited by the first melt bonded part 8 and the two second melt bonded parts 11, extends in longitudinal direction of the substrate sheet 12 and the holding sheet 13 and opens at both longitudinal ends, so that the insertion part 16 of the holder 15 can be inserted in the receiving part 14.
The substrate sheet 12 and the holding sheet 13 are melt bonded to the first fibrous member 3 of the brush part 2 at center portion thereof by the second melt bonded part forming device 134 to be described later, and as shown in FIG. 3, a pair of melt bonding lines 18 is formed in the cleaning member 1 at a prescribed separation in width direction of the substrate sheet 12 and the holding sheet 13, and the first melt bonded part 8 is formed between the pair of melt bonding lines 18. The pair of melt bonding lines 18 is a mark for controlling the position of the first melt bonded part 8 in manufacture stage, and by controlling whether or not the first melt bonded part 8 is situated between the pair of heat melt bonding lines 18, selection between defective and non-defective product can be carried out.
As shown in FIGS. 1 to 3, two second melt bonded parts 11 are provided intermittently in longitudinal direction of the substrate sheet 12 and the holding sheet 13, and by engaging circular arc-shaped protrusion 16 a of each insertion part 16 of the holder 15 with the non-fusion portion of the two second melt bonded parts 11, each insertion part 16 of the holder 15 is prevented from slipping out of each receiving part 14.
As shown in FIG. 1, incisions 20 a in the shape of saw tooth are provided at a prescribed separation along longitudinal direction on both edge portions (portions outside of two second melt bonded parts 11) in width direction of the substrate sheet 12 and the holding sheet 13, and with these incisions 20 a, plural reed-shaped parts 20 with both edges in the shape of saw tooth are provided. In other embodiment, incisions 20 a in the shape of saw tooth are provided in the substrate sheet 12 and the holding sheet 13, and therefore, no reed-shaped part 20 is formed.
As shown in FIG. 1, the holder 15 has a pair of insertion parts 16 in the shape of rectangular plate arranged in parallel to each other, a pair of circular arc-shaped protrusions 16 a projecting from outer side of both longitudinal ends of each insertion part 16, and a holder part 17 integrally provided on one end of the insertion part 16, and is formed of, for example, plastic and the like.
By inserting both insertion parts 16 of the holder 15 into both receiving parts 14 of the cleaning member 1 and engaging the protrusions 16 a with the non-fusion portion of the two second melt bonded parts 11, the cleaning member 1 is mounted to the holder 15. By holding the holder part 17 of the holder 15 and bringing the brush part 2 into contact with the point to be cleaned and moving it in desired direction, dust and dirt at the point to be cleaned are captured by the brush part 2 and the point to be cleaned is cleaned.
Next, an embodiment of the method and apparatus for manufacturing a cleaning member 1 will be described with reference to FIG. 4.
FIG. 4 is a schematic view useful for explaining the method and apparatus for manufacturing a cleaning member 1, and in the present embodiment, the apparatus 100 shown in FIG. 4 is used to carry out the method for manufacturing the cleaning member 1 and the cleaning member 1 is manufactured.
In the present embodiment, the manufacturing method for manufacturing the cleaning member 1 comprises the following steps 1 and 2.
[Step 1] Step of manufacturing a fiber bundle having an oil agent attached thereto.
[Step 2] Step of using the fiber bundle having the oil agent attached thereto to manufacture a continuous body of cleaning members and cutting out the cleaning member 1 from the continuous body of cleaning members.

Step 1 will be described below
In the present embodiment, step 1 includes the following steps 1a and 1b
[Step 1a] Step of opening a first fiber bundle F1 to a fourth fiber bundle F4.
[Step 1b] Step of applying an oil agent to the first fiber bundle F1 to the fourth fiber bundle F4.
In the present embodiment, although step 1 includes step 1a, presence or absence of step 1a may be suitably selected in accordance with type of the fiber bundle used. In other embodiment, step 1a may be omitted. For example, if the fiber bundle is composed of non-crimped fiber, step 1a can be omitted.

[Step 1a]

Step 1a will be described below taking a step of opening the first fiber bundle F1 as an example. Steps of opening other fiber bundles (the second fiber bundle F2 to the fourth fiber bundle F4) are carried out in the same way.
The first fiber bundle F1 composed of crimped fibers is drawn out continuously from a storage container (not shown), and is fed to a first nip rollers 102 a, 102 b rotating at a constant peripheral velocity V1. The first fiber bundle F1 passing past the first nip roller 102 a, 102 b is, after passing plural tension rollers 104, fed to a second nip rollers 106 a, 106 b rotating at peripheral velocity V2.
The peripheral velocity V2 of the second nip rollers 106 a, 106 b is higher than the peripheral velocity V1 of the first nip rollers 102 a, 102 b. Owing to this difference between the peripheral velocities, tension is imparted to the first fiber bundle F1 between the first nip rollers 102 a, 102 b and the second nip rollers 106 a, 106 b, and as a result, the first fiber bundle F1 is opened.
Each tension roller 104 is formed of, for example, solid steel, and its mass is adjusted such that significant force is required for rotation. Therefore, when the first fiber bundle F1 advances from the first nip rollers 102 a, 102 b to the second nip rollers 106 a, 106 b while rotating each tension roller 104, speed of movement of the first fiber bundle F1 is not increased suddenly.
Each of the tension rollers 104 is disposed such that, in order to open the first fiber bundle F1 slowly, the distance from the first nip rollers 102 a, 102 b to the second nip rollers 106 a, 106 b is sufficiently long.
After passing the second nip rollers 106 a, 106 b, the first fiber bundle F1 passes an air supplying device 108, and is fed to the third nip rollers 112 a, 112 b rotating at peripheral velocity V3. The peripheral velocity V3 of the third nip rollers 112 a, 112 b is lower than the peripheral velocity V2 of the second nip rollers 106 a, 106 b. Owing to this difference between the peripheral velocities, tension of the first fiber bundle F1 is relaxed between the second nip rollers 106 a, 106 b and the third nip rollers 112 a, 112 b, and as a result, the first fiber bundle F1 is opened further and the width of the first fiber bundle F1 is increased.
While the first fiber bundle F1 is fed from the second nip rollers 106 a, 106 b to the third nip rollers 112 a, 112 b, air is blown to the first fiber bundle F1 by the air supplying device 108, and as a result, the first fiber bundle F1 is further opened.
In the present embodiment, opening of the first fiber bundle F1 is promoted by imparting and relaxing of tension and blow of air. But, a method for opening the fiber bundle may be suitably modified. In other embodiment, only one of imparting and relaxing of tension and blow of air is used. In still other embodiment, other methods of opening the fiber bundle are used in addition to imparting and relaxing of tension and blow of air. Although, in the present embodiment, the first to the third nip rollers are used for imparting and relaxing tension, the number of nip rollers may be suitably chosen. In other embodiment, in addition to the first to the third nip rollers, other nip rollers may be used.

[Step 1b]

Step 1b will be described below taking a step of applying an oil agent to the first fiber bundle F1 as an example. Steps of applying an oil agent to other fiber bundles (the second fiber bundle F2 to the fourth fiber bundle F4) are carried out in the same way.
Step 1b is carried out using a transfer roller 110 provided between the second nip rollers 106 a, 106 b and the third nip rollers 112 a, 112 b. Thus, in the present embodiment, step 1b is carried out between the second nip rollers 106 a, 106 b and the third nip rollers 112 a, 112 b, that is, during step 1a. However, time for carrying out step 1b may be suitably modified. In other embodiment, step 1b is carried out after step 1a.
The transfer roller 110 is a roller generally used as a roll coater, and is not particularly limited as long as a film of an oil agent can be formed on the roller surface, and is preferably a mirror surface roller. If the transfer roller 110 is a mirror surface roller, the first fiber bundle F1 is prevented from winding around the transfer roller 110, and a cleaning member comprising a fiber bundle having an oil agent uniformly attached thereto can be manufactured efficiently. Rollers that can be used as the transfer roller 110 include, in addition to a mirror surface roller, a roller with surface formed of porous ceramics (for example, a metal roller coated or vapor-deposited with porous ceramics), a roller with metal plating and satin finish on the surface, for example.
As the diameter of the transfer roller 110 is increased, the area of contact with the first fiber bundle F1 is increased so that uniformity of the transferred oil agent is improved. If, however, the diameter becomes too large, the feeding of the first fiber bundle F1 may be impeded, and the size of the equipment also needs to be increased. On the other hand, as the diameter of the transfer roller 110 is decreased, the area of contact with the first fiber bundle F1 is also decreased and the feeding of the first fiber bundle F1 is not impeded so that the size of the equipment can be reduced. If, however, the diameter becomes too small, uniformity of the transferred oil agent is lowered. Therefore, the diameter of the transfer roller 110 is suitably adjusted taking account of these points. The width (length in axial direction) of the transfer roller 110 is adjusted so as to be larger than the width of the first fiber bundle F1 between the second nip rollers 106 a, 106 b and the third nip rollers 112 a, 112 b.
The rotational speed of the transfer roller 110 is suitably adjusted with the feeding velocity of the first fiber bundle F1 and the diameter of the transfer roller 110 taken into account such that a film of oil agents is formed on the surface of the roller. For example, if the feeding velocity of the first fiber bundle F1 is 5 to 100 m/min, the rotational speed of the transfer roller 110 may be adjusted to 5 to 0.5 rpm. In a preferred embodiment, the feeding velocity of the first fiber bundle F1 is 23.1 m/min, the diameter of the transfer roller 110 is 214 mm, and the rotational speed of the transfer roller 110 is 1.375 rpm.
The transfer roller 110 is provided such that, with a driving system, it is brought into contact with the first fiber bundle F1 while being rotated in a direction opposite to the feeding direction D1 of the first fiber bundle F1. The expression “a direction opposite to the feeding direction D1 of the first fiber bundle F1” means that the direction of the tangential velocity of the portion of the transfer roller 110 contacting with the first fiber bundle F1 is opposite to the feeding direction D1 of the first fiber bundle F1.
As shown in FIG. 4, an oil agent bath 114 is provided at a position upstream of the contact point of the first fiber bundle F1 and the transfer roller 110 in rotating direction of the transfer roller 110. With such construction, before a prescribed portion of the surface of the transfer roller 110 comes into contact with the first fiber bundle F1, an oil agent is applied to the prescribed portion.
An oil agent is contained in the oil agent bath 114. In the present embodiment, the oil agent contained in the oil agent bath 114 is a dust collecting oil agent (for example, an oil agent including liquid paraffin as a main component).
The amount of the oil agent contained in the oil agent bath 114 and the position of the rotational axis of the transfer roller 110 is adjusted such that a portion of the transfer roller is dipped in the oil agent contained in the oil agent bath 114. The transfer roller 110 is rotated with a portion thereof dipped in the oil agent bath 114 so that the oil agent is continuously applied to the surface of the transfer roller 110. The amount of the applied oil agent is adjusted such that the amount of the oil agent per one cleaning member is usually 0.05 to 2 g/piece, preferably 0.1 to 1 g/piece, and more preferably 0.2 to 0.5 g/piece. If the dust collecting oil agent is an oil agent having liquid paraffin as a main component, the viscosity of the oil agent is preferably 108 to 128 mm²/S. This viscosity is the viscosity as measured by Ubbelohde method (30° C.) carried out using an Ubbelohde viscometer (defined in JIS K 2839-1980 with coefficient determined in SIS B-0017), a thermometer (defined in JIS B7410-1982 for dynamic viscosity measurement) and a thermostat (defined in JIS K2283-1983).
A blade member 113 is provided at a position upstream of the contact point of the first fiber bundle F1 and the transfer roller 110 in rotating direction of the transfer roller 110 and downstream of the position of the oil agent bath 114 in rotating direction of the transfer roller 110 in order to scrape off an excess of the oil agent applied to the surface of the transfer roller 110. With this construction, before the prescribed portion of the surface of the transfer roller 110 comes into contact with the first fiber bundle F1 and after the oil agent is applied to the prescribed portion, an excess of the oil agent applied to the prescribed portion is scraped off. By scraping off an excess of the oil agent applied to the surface of the transfer roller 110, the blade member 113 achieves a uniform thickness of the oil agent applied to the surface of the transfer roller (so as to form a thin film).
In the present embodiment, the blade member 113 is used to achieve a uniform thickness of the oil agent applied to the surface of the transfer roller 110 (so as to form a thin film), the same effect can be obtained by using other member. In other embodiment, a roll 115 may be disposed, as shown in FIG. 5, at a position upstream of the contact point of the first fiber bundle F1 and the transfer roller 110 in rotating direction of the transfer roller 110 and downstream of the position of the oil agent bath 114 in rotating direction of the transfer roller 110 in order to scrape off an excess of the oil agent applied to the surface of the transfer roller 110 in a constant clearance (separation) to the transfer roller 110. In this embodiment, as shown in FIG. 5, by rotating the transfer roller 110 and the roll 115 in opposite direction at a position for achieving a uniform thickness of the oil agent applied to the surface of the transfer roller 110 (so as to form a thin film), a uniform thickness of the oil agent 116 applied to the surface of the transfer roller 110 can be effectively achieved (so as to form a thin film).
When the first fiber bundle F1 continuously fed by the second nip rollers 106 a, 106 b and the third nip rollers 112 a, 112 b in the prescribed direction D1 comes into contact with the transfer roller 110 rotated in the direction opposite to the feeding direction D1 of the first fiber bundle F1, the oil agent applied on the surface of the surface of the transfer roller 110 is transferred to the first fiber bundle F1. In this manner, the first fiber bundle having the oil agent attached thereto is manufactured. The transfer roller 110 is rotated with a portion thereof dipped in the oil agent bath and with another portion thereof in contact with the first fiber bundle F1, so that the oil agent is continuously transferred to the first fiber bundle F1 that is continuously fed in the prescribed direction D1. By using the transfer roller 110 rotated in the direction opposite to the feeding direction D1 of the first fiber bundle F1, the oil agent is accumulated between the first fiber bundle F1 and the transfer roller 110 at a position upstream of the contact point of the transfer roller 110 with the first fiber bundle F1 in the rotating direction of the transfer roller 110, so that the oil agent can be uniformly attached to the first fiber bundle F1 with no irregularity.
Between the second nip rollers 106 a, 106 b and the third nip rollers 112 a, 112 b, the first fiber bundle F1 is held in a floating state, and the first fiber bundle F1 comes into contact with the transfer roller 110 in floating state. The term “floating state” means that, when a force is exerted to the first fiber bundle F1, the first fiber bundle F1 is free to move in the direction of the exerted force. For example, if, when the first fiber bundle F1 comes into contact with the transfer roller 110, a force is exerted by the transfer roller 110 in upward direction in FIG. 4, the first fiber bundle F1 is free to be moved in upward direction in FIG. 4, and when the force is released, it is free to move in downward direction in FIG. 4.
In order to ensure the floating state of the first fiber bundle F1, no member which presses the first fiber bundle F1 to the transfer roller 110 is provided at the position of contact of the first fiber bundle F1 with the transfer roller 110 on the side of the first fiber bundle F1 opposite to the transfer roller 110.
By holding the first fiber bundle F1 in floating state and bringing it into contact with the transfer roller 110 rotated in the direction opposite to the feeding direction D1 of the first fiber bundle F1, the oil agent can be uniformly attached to the first fiber bundle F1 with no irregularity, and unlike the case where a backup roller is used to press the first fiber bundle F1 against the transfer roller 110, there is no risk of the first fiber bundle F1 being wound around the backup roller and impeding transport of the first fiber bundle F1. Therefore, with the present embodiment, a cleaning member comprising a fiber bundle having an oil agent uniformly attached thereto with no irregularity can be efficiently manufactured.
After being processed in step 1, the first fiber bundle F1 proceeds to the confluence point 132. Similarly, after being processed in step 1, the second fiber bundle F2 to the fourth fiber bundle F4 proceed to the confluence points 136, 138, 140, respectively.

Step 2 will be described below.
In the present embodiment, step 2 includes following steps 2a to 2 c.
[Step 2a] After being processed in step 1, the fiber bundle is stacked to other member (in the present embodiment, belt-shaped non-woven fabric) to form multilayer web.
[Step 2b] Fixing the fiber bundle to other member included in the multilayer web.
[Step 2c] Cutting out individual cleaning members from the multilayer web.

[Step 2a]

Step 2a will be described below.
In the present embodiment, other members to be stacked to the fiber bundle after being processed in step 1 are belt-shaped non-woven fabrics 121, 123, 151. In other embodiment, one or two of these non-woven fabrics are stacked to the fiber bundle after being processed in step 1. In still other embodiment, in addition to these non-woven fabrics, other non-woven fabric is stacked to the fiber bundle that has been processed in step 1. In any of these embodiments, although the order of superposition is not particularly limited, a non-woven fabric is preferably stacked so as to be situated at the outermost position.
The non-woven fabrics 121, 123 correspond respectively to the substrate sheet 12 and to the holding sheet 13. The non-woven fabric 121 is continuously rolled out from the non-woven fabric roll 120 and includes plural rollers disposed in two rows, upper rollers and lower rollers, and is intermittently conveyed by the roll situated in lower row passing the dancer roller 124 swinging up and down. Similarly, the non-woven fabric 123 is continuously rolled out from the non-woven fabric roll 122 and includes plural rollers disposed in two rows, upper rollers and lower rollers, and is intermittently conveyed by the roll situated in lower row passing the dancer roller 126 swinging up and down. The expression “intermittently conveyed” means that each of the non-woven fabrics 121, 123 is conveyed such that it advances for certain distance (for example, about the length in width direction of a cleaning member 1) in the feeding direction and then conveyance is stopped for certain time period, and this cycle is repeated. By conveying the non-woven fabrics 121, 123 intermittently in this manner, time required for fusion of the constituents of the multilayer web can be ensured, as will be described later.
The non-woven fabrics 121, 123 join at the confluence point 128 to form multilayer web S1, and the multilayer web S1 passes through a gather cutter 130 having saw tooth-shaped blade (not shown) formed intermittently in circumferential direction on its surface. With this cutter, incisions corresponding to the incisions 20 a (see FIG. 1) of the substrate sheet 12 and the holding sheet 13 are formed.
The multilayer web S1 joins at the confluence point 132 to the first fiber bundle F1 that has been processed in step 1, and the first fiber bundle F1 is stacked onto the multilayer web S1 to form a multilayer web S2. At this time, the construction is such that the first fiber bundle F1 can slacken to some extent between the third nip rollers 112 a, 112 b and the confluence point 132, and with such construction, same effect as provision of a dancer roller between them can be obtained.
The multilayer web S2 successively joins at confluence points 136, 138, 140 to the second fiber bundle F2 to the fourth fiber bundle F4 that have been processed in step 1, and the second fiber bundle F2 to the fourth fiber bundle F4 are successively stacked onto the multilayer web S2 to form a multilayer web S3.
The non-woven fabric 151 corresponds to the sheet with slits 7. The non-woven fabric 151 is rolled out continuously from a non-woven fabric roll 150, and by passing through a dancer roller 152, is conveyed intermittently and passes through a gather roller 154. The gather roller 154 has a saw tooth-shaped blade (not shown) formed continuously in circumferential direction on the surface, and with this roller, saw tooth-shaped incision (not shown) is formed in the non-woven fabric that has passed the gather roller 154.
The non-woven fabric 151 joins at the confluence point 156 to the multilayer web S3, and the non-woven fabric 151 is stacked on the multilayer web S3 to form a multilayer web S4.

[Step 2b]

Step 2b will be described below.
Before joining to the second fiber bundle F2 to the fourth fiber bundle F4, the multilayer web S2 passes the second melt bonded part forming device 134. The second melt bonded part forming device 134 fuses the non-woven fabrics 121, 123 and the first fiber bundle F1 included in the multilayer web S2 to form two second melt bonded parts 11 (see FIG. 3). Thus, the multilayer web S2 is fused through thickness direction. In the present embodiment, a heat sealing device is used as the second melt bonded part forming device 134. However, the second melt bonded part forming device may be suitably changed. In other embodiment, an ultrasonic sealing device may be used.
The multilayer web S4 passes the first melt bonded part forming device 158. The first melt bonded part forming device 158 fuses the entire multilayer web S4 and form the first melt bonded part 8 (see FIG. 3, etc.) in the multilayer web S4. With this fusion, the multilayer web S4 is fused through its thickness direction. Although, in the present embodiment, a heat sealing device is used as the first melt bonded part forming device 154, the melt bonded part forming device may be suitably changed. In other embodiment, an ultrasonic sealing device may be used.

[Step 2c]

Step 2c will be described below.
The multilayer web S4 passing the first melt bonded part forming device 158 is cut in a cutter unit 160 and individual cleaning members 1 are cut out.
The cleaning member 1 manufactured in the present embodiment includes a sheet with slits 7. However, the sheet with slits 7 is not included in the cleaning member manufactured in other embodiment. Also, in the cleaning member 1 manufactured in the present embodiment, the counter-insertion unit 14 is situated on the surface of the cleaning member 1. However, in the cleaning member manufactured in other embodiment, by changing the order of superimposition of the substrate sheet 12 and the holding sheet 13 and the fibrous members 3 to 6, the counter-insertion unit 14 is disposed between any of adjoining fibrous members 3 to 6. With such construction, both faces of the cleaning member 1 can be used in cleaning. In this case, in order to facilitate insertion of the insertion part 16 into the receiving part 14, dimension in longitudinal direction (up-down direction in FIG. 3) of the substrate sheet 12 and the holding sheet 13 is preferably larger than that of the fibrous members 3 to 6, and this dimension can be arbitrarily chosen. Also in this case, the sheet with slits 7 may or may not be used, and the sheets with slits 7 may be disposed on both face of the cleaning member 1.
The cleaning member illustrated in FIG. 1 to FIG. 3 is an example of the cleaning members which can be produced using the method of producing a cleaning member and the system of producing a cleaning member according to the present disclosure. The method of producing a cleaning member and the system of producing a cleaning member according to the present disclosure can be used to produce a cleaning member as described in, for example, Japanese Unexamined Patent Publication No. 2000-296083, 2003-265390, 2003-268663, 2004-223692, 2005-046645, 2005-095665, 2005-111284, 2005-137929, 2005-137930, 2005-137931, 2005-144198, 2005-169148, 2005-199077, 2005-230573, 2005-237975, 2006-015164, 2006-034990, 2006-141483, 2007-135774, 2007-209460, 2007-209461, 2007-029136, 2007-111297, 2007-135666, 2007-136156, 2007-159612, 2007-236690, 2008-006260, 2008-119171, and 2007-029135, the entire disclosures of which are incorporated herein by reference.
The method of producing a cleaning member and the system of producing a cleaning member according to the present disclosure can be used to produce a cleaning member as described in, for example, U.S. Pat. No. 6,554,937B, US2002/148061A, US2003/0000934A, US2004/0149095A, US2005/0005381A, US2005/039285A, US2005/097695A, US2005/097696A, US2005/132521A, US2005/177967A, US2005/188490A, US2005/193513A, US2005/193514A, US2005/198760A, US2006/016035A, US2006/016036A, US2006/101601A, US2009/165230A and US2009/172904A, as well as US2009/049633A, US2009/255078A and US2010/154156A, the entire disclosures of which are incorporated herein by reference.
The present application claims the benefit of the following patent applications, the entire disclosures of which are incorporated herein by reference:
(1) JP Patent Application No. 2012-289181 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(2) JP Patent Application No. 2012-289182 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(3) JP Patent Application No. 2012-289174 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(4) JP Patent Application No. 2012-289189 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(5) JP Patent Application No. 2012-289175 filed on Dec. 29, 2012,
(6) JP Patent Application No. 2012-289188 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(7) JP Patent Application No. 2012-289179 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(8) JP Patent Application No. 2012-289177 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(9) JP Patent Application No. 2012-289184 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(10) JP Patent Application No. 2012-289178 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(11) JP Patent Application No. 2012-289176 filed on Dec. 29, 2012, and US patent application claiming priority thereof,
(12) JP Patent Application No. 2013-002855 filed on Jan. 10, 2013, and US patent application claiming priority thereof, as well as
(13) JP Patent Application No. 2013-002857 filed on Jan. 10, 2013, and US patent application claiming priority thereof.

REFERENCE SIGNS LIST

1—cleaning member, 2—brush part, 3—first fibrous member, 4—second fibrous member, 5—third fibrous member, 6—fourth fibrous member, 7—sheet with slits, 8—first melt bonded part, 11—second melt bonded part, 12—substrate sheet, 13—holding sheet, receiving part, 15—holder, 16—insertion part, 16 a—protrusion, 17—holder part, 18—melt bonding line, 20—reed shaped part, 20 a—incision, 100—apparatus for manufacturing cleaning member, 102 a, b—first nip roller, 104—tension roller, 106 a, b—second nip roller, 108—air supplying device, 110—transfer roller, 112 a, b—third nip roller, 113—blade member, 114—oil agent bath, 115—roll, 116—oil agent, 120, 122, 150—non-woven fabric roll, 121, 123, 151—belt-shaped non-woven fabric, 124, 126, 152—dancer roller, 128, 132, 136, 138, 140, 156—confluence point, 130—gather cutter, 134—second melt bonded part forming device, 154—gather roll, 158—first melt bonded part forming device, 160—cutter unit

Claims

1. A method for manufacturing a cleaning member including a fiber bundle having an oil agent attached thereto, the method comprising a step of:

bringing the fiber bundle continuously fed in a prescribed direction into contact with a roller rotated in a direction opposite to the feeding direction of the fiber bundle so as to transfer the oil agent applied on the surface of the roller to the fiber bundle.

2. The method according to claim 1, wherein the fiber bundle is brought into contact with the roller while the fiber bundle is held in a floating state.

3. The method according to claim 1, wherein the roller is a mirror surface roller.

4. The method according to claim 1, further comprising a step of applying the oil agent to the surface of the roller before bringing the fiber bundle into contact with the roller.

5. The method according to claim 4, wherein the oil agent is applied to the surface of the roller by rotating the roller with a portion thereof being dipped in a bath containing the oil agent.

6. The method according to claim 4, further comprising a step of achieving a uniform thickness of the oil agent applied to the surface of the roller before bringing the fiber bundle into contact with the roller and after applying the oil agent to the surface of the roller.

7. An apparatus for manufacturing a cleaning member including a fiber bundle having an oil agent attached thereto, the apparatus comprising:

a fiber bundle feeding unit that feeds the fiber bundle in a prescribed direction;

a roller provided so as to come into contact with the fiber bundle while being rotated in a direction opposite to the feeding direction of the fiber bundle; and

an oil agent application unit that applies the oil agent to the surface of the roller before the roller comes into contact with the fiber bundle.

8. The apparatus according to claim 7, wherein any member which presses the fiber bundle to the roller is not provided.

9. The apparatus according to claim 7, wherein the roller is a mirror surface roller.

10. The apparatus according to claim 7, wherein the oil agent application unit applies the oil agent to the surface of the roller by rotating the roller with a portion thereof being dipped in a bath containing the oil agent.

11. The apparatus according to claim 7, further comprising a blade member which scraps off an excess of the oil agent applied to the surface of the roller before bringing the fiber bundle into contact with the roller and after applying the oil agent to the surface of the roller.

12. The apparatus according to claim 7, further comprising a roll provided at a certain clearance to the roller so as to achieve a uniform thickness of the oil agent applied to the surface of the roller before bringing the fiber bundle into contact with the roller and after applying the oil agent to the surface of the roller.