JP2847135B2 - Apparatus and method for manufacturing nonwoven fabric mat - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and a method for manufacturing a nonwoven fabric mat, and more particularly, to a process for manufacturing a nonwoven fabric mat using a cross layer, in which a band-like fiber accumulation is performed. The present invention relates to an apparatus and a method for producing a nonwoven fabric mat having different thicknesses by using both ears of a body to change the basis weight.

[Conventional technology]

A nonwoven fabric mat, particularly a nonwoven fabric mat as a molding substrate used for an interior material such as an automobile ceiling or the like, sometimes requires a large rigidity.

In such a case, the above requirement has been satisfied by increasing the weight per unit area of the entire nonwoven fabric mat (hereinafter referred to as the basis weight) and improving the rigidity of the entire mat.

However, when this means is used, the basis weight is increased to a portion where a large rigidity is not required, and the whole nonwoven fabric mat may become unnecessarily heavy.

Separately, for example, in Japanese Patent Application Laid-Open No. 58-98463,
The band-shaped strand laminate not treated with the cross layer is first sent to a fiber entanglement needler to form a glass fiber mat, and the tapered both ears of the glass fiber mat caused by the needler are cut (logically). Cuts along the middle line of the tapered ears.), Flips the ears outside the cut line inward, and then turns the inverted ears into a glass fiber mat with a needler to prevent misalignment. A technique of integrating them is disclosed.

However, the above-mentioned conventional technology does not manufacture a nonwoven fabric mat having a partially different thickness by changing the basis weight,
It is assumed that a uniform single weight distribution mat is manufactured.

Further, the above-mentioned conventional technique is a device for not discarding the tapered ears, since a large amount of tapered ears is generated when needle-punching the band-shaped strand laminate not processed by the cross layer. .

However, the object of the present invention is to provide a nonwoven fabric mat having a partially different thickness due to a change in the basis weight in a band-shaped fiber assembly which is basically basically a uniform single weight distribution secured by using a cross layer. Is to manufacture. Moreover, since the belt-like fiber assembly formed by using the cross layer is relatively less likely to form a large amount of tapered ears even when needle-punched as a common technical knowledge, the above technique is not very useful.

More specifically, when the above-mentioned prior art is applied for the purpose of the present invention, a tapered ear portion is first generated by a needle punching machine for fiber entanglement, which makes it difficult to treat the ear. This is because if this is used, the basis weight is changed in a tapered shape. Therefore, for the purpose of the present invention, the tapered ears are discarded, and again, the ears are cut from the band-shaped fiber assembly to change the weight per unit area. It will be lost. In addition, if it is desired to prevent displacement of the stacked ears, a second means such as a needler for preventing displacement is required.

[Problems to be solved by the invention]

In the present invention, the fiber group supplied on the transport device is formed into a band-shaped fiber aggregate by a cross layer, and the basis weight is changed efficiently without waste using the both ears of the band-shaped fiber aggregate. An object of the present invention is to provide an apparatus and a method for manufacturing a nonwoven fabric mat having a partially different thickness.

[Means for solving the problem]

In order to solve the above-described problems, the nonwoven fabric mat manufacturing apparatus according to the present invention includes a band-shaped fiber assembly forming section including a cross layer on the upstream side of the manufacturing line and a band-shaped fiber aggregate on the downstream side of the manufacturing line. And a needle punching machine for forming a nonwoven fabric mat for entanglement of the fibers, and both ears of the band-shaped fiber assembly are longitudinally arranged between the band-shaped fiber assembly forming section and the needle punching machine. It is characterized by including a cutting unit for cutting along the direction, and a basis weight changing unit including a conveyer for lamination for laminating the cut both ears to the belt-shaped fiber assembly.

The method for producing a nonwoven fabric mat according to the present invention, in order to solve the above-mentioned problems, comprises forming a group of fibers supplied on a conveying device into a band-like fiber aggregate by a cross layer, and then using a cutting device to form the band-like fiber aggregate. Cut the both ears along the longitudinal direction, and change the basis weight of the band-shaped fiber assembly by laminating the both ears on the band-shaped fiber assembly using a laminating conveyor, and then form a nonwoven fabric mat. The fibers of the band-shaped fiber assembly are entangled by the needle punching machine.

[Action / Effect]

ADVANTAGE OF THE INVENTION According to the manufacturing apparatus of the nonwoven fabric mat and the manufacturing method of the nonwoven fabric mat according to the present invention, for the band-shaped fiber aggregate formed by the cross layer, before the needle punching for fiber entanglement, the both ears are cut. Since the basis weight of the band-shaped fiber assembly is changed by laminating the band-shaped fiber assembly, a tapered ear portion does not occur, and there is no problem that the basis weight is changed in a tapered shape.

Further, since the needle punching for the fiber entanglement in the next step is performed after the lamination of the ear portions, even if it is desired to prevent the positional deviation of the laminated ear portions, the needle punching also serves as a positional deviation preventing means.

Further, the cross-layer type band-shaped fiber assembly does not generate a large amount of tapered ears even by needle punching for fiber entanglement, so that there is little waste. Then, when a slight protruding portion in the form of an ear is generated and the user is worried, it can be simply cut off.

(Embodiment of the invention)

(Embodiment 1) In the embodiment of the present invention, the ear separated from the band-shaped fiber assembly is stacked on the band-shaped fiber assembly without being turned upside down.

Because, even though it is basically a band-shaped fiber aggregate that has a uniform uniform weight distribution using a cross layer,
Since both end portions are folded portions in the cross layer, there is a slight increase in the weight per unit area as compared with other portions, and a slightly irregular meandering shape of the end side. When the cut ears are turned upside down with respect to the band-shaped fiber assembly and laminated, the folded portion comes to a position closer to the center of the band-shaped fiber assembly, so it is slightly undesirable at the following two points. is there.

There is a relatively large step at the boundary between the one-layer portion (center portion) and the two-layer portion of the fiber assembly, which tends to make subsequent processing such as molding difficult.

For the fold with a slightly irregular meandering shape,
Partial and irregular changes in the basis weight occur in this portion, making it difficult to make the quality and physical properties uniform in the longitudinal direction of the nonwoven fabric mat.

(Embodiment 2) In the embodiment of the present invention, the ear part separated from the band-shaped fiber assembly is not turned upside down with respect to the band-shaped fiber assembly, and the width of the band-shaped fiber assembly after the ear part is cut. It is laminated so as to substantially overlap both ends in the direction.

Because of this, the operation
This is because, in addition to the effect, the edges of the slightly irregular meandering shape at the ears can be easily cut off to uniform the quality and physical properties in the longitudinal direction of the nonwoven fabric mat.

In this cutting operation, when a small ear-shaped protruding portion is formed in the band-shaped fiber assembly due to the needle punching for the fiber entanglement, the cutting can be performed together with the protruding portion, so that there is no waste in the process.

〔Example〕

FIGS. 1 and 2 show an embodiment of the present invention in which open fibers (not shown) are used to open raw cotton into individual fibers, and the opened fiber group is cross-layered. (Not shown). The cross layer forms the opened fiber group in a band shape, and folds the band on the conveyor 1 in a direction substantially perpendicular to the conveying direction.
The fiber assembly 2 which is a precursor of the nonwoven fabric mat is formed.
At this time, the width of the fiber assembly 2 is 1900 mm, and the basis weight is 150 g /
m ² , the constituent fibers are made of polyethylene or polypropylene and glass fibers. Among the above, the organic fibers act as a binder for the inorganic fibers, and therefore, polyolefin fibers having a relatively low melting point are desirable, and low-melting polyester fibers may be used in place of the polyolefin fibers. In terms of fiber length, both inorganic and organic fibers
Fibers of 25 mm to 75 mm can be used, and more preferably, fibers having a length of about 50 mm are suitable.

The fiber stack 2 formed by the cross layer is conveyed to the next process at a speed of 5 m / min by the conveyor 1 to cut both widthwise ears of the fiber stack 2 downstream of the cross layer. Lower roller 3 and cutting blade 4,
5 are provided. The cutting blades 4 and 5 are
The width of the ears 6, 7 cut from the fiber assembly 2 is determined by how much the fiber assembly 2 is attached to a position closer to the center of the fiber assembly 2 in the width direction. In the present embodiment, The positions of the cutting blades 4 and 5 are adjusted so that the width of both ears is 250 mm. Of both the ears 6 and 7 divided by the cutting blades 4 and 5 and the central part 8, the central part 8 is the same 5 m / min as before the division by the second transport conveyor 9 and the third transport conveyor 10. At the transfer speed of Both ears 6, 7 are connected to the first laminating conveyor 111.
2. It is transported separately from the central part 8 by the second laminating conveyors 13 and 14.

Specifically, by the first lamination conveyors 11, 12,
The two ears 6 and 7 are conveyed obliquely upward, respectively, so as to be separated from the central part 8 and then to the second laminating conveyor.
While being moved toward the central part of the central part 8 by 13 and 14, it is conveyed obliquely downward, and both ear parts 6, 7 are laminated on both ends in the width direction of the central part 8, respectively.

At this time, the right end of the central portion 8 with respect to the transport direction of the fiber assembly
15 and the right edge 16 of the right ear 6, the left edge 17 of the center 8 and the left ear 7
Are laminated so that the left end sides 18 of the. The laminated fiber assembly 19 is introduced into the punching machine 20 by the third conveyor 10 and the constituent fibers of the laminated fiber assembly 19 are entangled with each other.
Tuck 19 to form a nonwoven mat.

In addition, the right end 16 of the right ear 6 and the left end 18 of the left ear 7 may have a slightly increased basis weight or meandering.
By cutting both ends of the 19 by an appropriate width and removing the disturbed edges, it is possible to manufacture a nonwoven fabric mat having little variation in the basis weight and a stable shape.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a main part of a manufacturing apparatus of the present invention, and FIG.
The figure is a plan view showing the main part of the manufacturing process of the nonwoven fabric mat of the present invention. 1, 9, 10: Conveyor 2: Fiber aggregate 4, 5, Cutting blade 6, 7, Ear 8: Central part 11, 12, 13, 14 ... Conveyor for lamination 19: Lamination Fiber assembly 20 ... Punching machine

Claims (2)

(57) [Claims] 1. A needle punching machine for forming a nonwoven fabric mat for entanglement of the fibers of the band-shaped fiber assembly on the upstream side of the manufacturing line and a fiber-shaped band forming apparatus including a cross layer on the downstream side of the manufacturing line. And a cutting device that cuts both ears of the band-shaped fiber assembly along the longitudinal direction, between the band-shaped fiber assembly forming section and the needle punching machine, and the cut both ears An apparatus for manufacturing a nonwoven fabric mat, comprising: a unit for changing a weight per unit comprising a laminating conveyor for laminating a part on a belt-shaped fiber assembly. 2. The method according to claim 1, wherein the fiber group supplied on the conveying device is formed into a band-like fiber aggregate by a cross layer, and both ears of the band-like fiber aggregate are cut along a longitudinal direction by a cutting device. The weight of the band-shaped fiber assembly is changed by laminating both ears to the band-shaped fiber assembly using a laminating conveyor, and then the fibers of the band-shaped fiber assembly are entangled by a needle punch machine for forming a nonwoven fabric mat. A method for producing a nonwoven fabric mat.