JP3069166B2 - Manufacturing method of polishing sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a commercial or household disposable polishing sheet for polishing metal, tableware and the like.

[0002]

2. Description of the Related Art Conventionally, to remove dirt strongly adhered to the surface of metal, glass, ceramics, plastics, and the like, a woven cloth, a nonwoven cloth, or a foam material is impregnated with a powder cleanser or a liquid cleanser containing an abrasive. Scratched. In order to solve the trouble of impregnating the nonwoven fabric, sponge, or the like with the polishing agent during such polishing, it has been proposed to bond the polishing agent to the nonwoven fabric by various methods. However, the impregnated abrasive is liable to fall off by any of the methods, and the polishing cloth is liable to be clogged unless washed frequently with water or the like.

On the other hand, Japanese Patent Application Laid-Open No. 51-1073 discloses a technique in which an abrasive is applied to a mesh to prevent the abrasive from clogging the mesh and reducing the polishing effect. Is disclosed. Also, Japanese Patent Application Laid-Open No. Sho 56-10
Japanese Patent No. 4634 discloses a technique in which a mesh is laminated on the surface of a fine fiber layer to capture abrasive powder in the fine fiber layer so that the abrasive powder does not directly touch the surface to be cleaned or the hand of a cleaner. Have been.

[0004] In this specification, the term "polishing powder" refers to dirt removed by polishing.

[0005]

However, in the former method, since the polishing powder is discharged to the surface to be polished, it is necessary to clean the polishing powder discharged to the surface to be polished.
There is a problem that polishing is troublesome because it requires wiping every time. Further, the latter method has a problem that the inner fine fiber layer merely captures the polishing powder and does not output the polishing powder to the surface of the polishing pad, so that a sufficient polishing action cannot be obtained.

It is therefore an object of the present invention is to provide a method for producing abrasive sheet that can be polished easily and sufficiently metals and dishes like without the use of abrasives.

[0007]

Means for Solving the Problems The present invention, first the fiber low melting point, and cotton mixing a second fiber having a high melting point, after forming a web by a carding machine to cotton mixing fibers, the first Polishing characterized by heating at a temperature higher than the melting point of the fiber and lower than the melting point of the second fiber to melt-bond the resin made of the first fiber to the surface of the second fiber while forming a nodular solid. To achieve the above objectives by providing a manufacturing method for
It has been achieved . Further, the present invention may alternatively <br/> method of manufacturing sheet for Migaku Ken, after forming the web by a carding machine the composite fibers comprising a low melting point component and a high melting point component, the melting point of the low melting component A polishing sheet characterized by being heated at a temperature higher than the melting point of the high melting point component to melt the low melting point component on the high melting point component, and to provide the high melting point component with bump-like irregularities. Is provided.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings. FIG. 1 shows a method for producing a polishing sheet of the present invention.
Is a perspective view showing cutaway of the polishing sheet produced by, Figure 2 is an enlarged view of the abrasive sheet shown in Figure 1, Figure 3 is a method of making an abrasive sheet shown in Figure 1 the is a diagram schematically illustrating, FIG. 4, sea polishing of the present invention
FIG. 5 is a perspective view showing a state of a fiber before heat-treating a fibrous web of a polishing sheet manufactured by the method for manufacturing a polishing sheet, and FIG. 5 is an enlarged view of the fibrous body shown in FIG. 4.

The polishing sheet 1 according to the present invention is characterized in that countless solid particles 3 made of a thermoplastic resin are provided on fibers 2 constituting the surface of the sheet. Such an abrasive sheet 1
Is manufactured as follows, as shown in FIG. At least a first fiber made of a thermoplastic resin (A) having a melting point equal to or higher than the heating temperature and a second fiber made of a thermoplastic resin (B) having a melting point equal to or lower than the heating temperature are mixed by a cotton mixing machine 5, and a card machine is used. After the web is formed by the method (7), the heat treatment is performed by the heater 9 to melt the thermoplastic resin (B) fiber of the second fiber on the thermoplastic resin (A) of the first fiber to form a nodule. It forms and imparts irregularities to the fibers.

[0010] The non-thermoplastic fiber (C) is mixed with the second fiber made of the thermoplastic resin (B) having a melting point below the temperature at which the non-thermoplastic fiber (C) thermally decomposes, and the card is machined. After the web is formed by 5, the non-thermoplastic fibrous fiber (C) is melted by heat treatment by a heater 9, so as to give bump-like irregularities. Further, a carding machine 7 is provided with a composite fiber obtained by compound-spinning a thermoplastic resin (A) having a melting point not lower than the heating temperature and a thermoplastic resin (B) having a melting point not higher than the heating temperature into a core-sheath type or a parallel type.
After forming into a web by heating, a heating process is performed by a heater 9 to melt the (B) fiber component on the (A) fiber component, thereby giving the thermoplastic resin (A) bump-like irregularities.

The thermoplastic fiber or the composite fiber made of thermoplastic resin used in the polishing sheet of the present invention includes polyolefins such as polyethylene, polypropylene and polybutene, polyesters such as polyethylene terephthalate, polybutylene terephthalate, and the like.
Vinyl-based, vinylidene-based, for example, polyvinyl chloride, polyvinylidene chloride, etc., amide-based such as nylon, and acrylic-based or modified products thereof, thermoplastics such as alloys and blends, and non-thermoplastic fibers such as rayon,
Cupra, cotton, hemp and the like are used. When a polishing sheet is obtained by combining thermoplastic fibers, a clear difference in melting point is required.

On the other hand, when non-thermoplastic fibers are used as a part of the polishing sheet, it is necessary to select thermoplastic fibers having a melting point below the temperature at which the fibers are thermally decomposed (carbonized). In addition, the nodules formed on the high melting point fibers or the non-thermoplastic fibers depending on the ratio of the low melting point thermoplastic fiber or the thermoplastic fiber component which is melted by heating and becomes the nodular irregularities. Since the number or size of the irregularities is affected, the ratio is appropriately selected depending on the polishing ability to be exhibited.

According to the method for producing a polishing sheet of the present invention ,
When the polishing sheet to be manufactured is used as a household polishing sheet and used for cleaning a sink or a range, the content of the low-melting fiber or its component which becomes knurled by heat treatment is preferably 30 to 95 wt%, and furthermore, Preferably 60 to 80
wt%. If the proportion of the low-melting fiber which becomes bulge-like irregularities by heat treatment is more than 95% by weight, the fibers are strongly adhered to each other, and it is difficult to form bulge-like irregularities. If the amount is less than 30 wt%, the number of bump-like irregularities is reduced or reduced, and the polishing ability is reduced.

On the other hand, when only the core-sheath type or parallel type composite fibers are used, the composite fiber diameter is increased by increasing the low melting point fiber component in order to increase or increase the size of the bumpy irregularities while maintaining the fiber diameter of the high melting point fibers. Thickness increases the processability of forming a fiber web, so that resinous fibers of the same quality or high compatibility with the low-melting point component are mixed so that the low-melting-point component becomes a predetermined amount. It is possible to control the amount or size of the irregularities. Furthermore, when the fiber diameter of the high melting point fiber is increased in order to improve the polishing ability or rigidity of the polishing sheet, by mixing resin fibers of the same or high compatibility with the low melting point component, the workability is improved. It is possible to obtain a good fiber diameter.

The nonwoven fabric web for capturing the abrasive powder is partially adhered or fused by a thermoplastic resin forming bump-like irregularities. As a method of forming a nonwoven fabric web, a fiber web is formed by a commonly used card in a general method, and then a heat treatment is performed at a temperature higher than the melting point of the low melting component and lower than the melting point of the high melting component, so that the low melting component is high. Nodular irregularities are formed in the fiber composed of the melting point component, and the fibers are fused or adhered to each other to form a nonwoven fabric web. At this time, the distance between the fibers constituting the nonwoven fabric web affects the entanglement retention between the stains and the fibers. Therefore, the degree of the inter-fiber distance is determined by comprehensively considering the polishing ability, the capture and retention of dirt, and the like, but a value of 30 to 500 μ is appropriate.

The inter-fiber distance a (m) is calculated by the following equation. a = (DV / 9000w) ^1/2 D: fineness (d) V: volume of nonwoven fabric (m ³ ) w: weight of nonwoven fabric (g) If less than 30μ, the distance between fibers can be held between fibers if too small. The amount of dirt decreases and the dirt retention deteriorates. If it is larger than 500 μm, the inter-fiber distance becomes too large, and the strength as a nonwoven fabric is remarkably reduced. In addition, the polishing ability of dirt and the like tend to be reduced. The strength of the nonwoven web also changes depending on the type, physical properties, basis weight, and the like of the constituent fibers.

The basis weight is also a polishing ability, a retention of dirt, strength,
It may be determined by comprehensively considering workability, cost, etc., but it is manufactured by the polishing sheet manufacturing method of the present invention.
When the polishing sheet is used as a household polishing sheet for cleaning a sink or a range, 10 to 150 g / m ² is appropriate. If the basis weight is less than 10 g / m ² , it is difficult to provide a necessary and sufficient polishing ability and strength. If the basis weight is more than 150 g / m ^2, it is disadvantageous in terms of cost.

Although the fineness also affects the polishing ability, the fineness of the high-melting fiber or non-thermoplastic fiber remaining as a fiber after the heat treatment is suitably 1 to 15 denier. If the thickness is smaller than 1 denier, the strength of the sheet becomes very poor. Incidentally, a surfactant or an oil agent may be contained in the base fabric in order to easily remove dirt adhered to the solid surface. The polishing effect can be controlled by selecting the hardness.

When used as a household polishing sheet for a sink or a range, the hardness of the fiber used for the nonwoven fabric web is determined by the Rockwell hardness test (JIS Z 2245).
In the above, it is preferable to use a resin having an R50 or more and M130 or less. Depending on the object to be polished, an abrasive may be applied to the nonwoven web. At that time, the abrasive may be any of those conventionally used in known polishing compositions.
At that time, the abrasives include those used in all conventionally known polishing compositions, for example, aluminum oxide, calcium carbonate, iron oxide, keishi, zeolite,
Feldspar, talc, quartz, phosphorous lime, chalcopyrite, garnet, molten zirconia, silicon carbide, boron carbide and the like. Also,
Thermosetting resins are used to bond abrasives to nonwoven webs,
It is also possible to use a binder obtained by dissolving a thermoplastic resin in a solvent, a commercially available adhesive, or the like, by a spray method, an immersion method, or the like. However, it is necessary to appropriately select the abrasive and the particle size depending on the object.

Further, the polishing sheet of the present invention is preferably
A method of making an abrasive sheet is a manufacturing method have is to cotton mixing the first and the fiber low melting point, a high melting point second textiles, cotton mixing
And after the fibers are formed into a web by a carding machine was, and heated at a first temperature lower than the higher second fiber melting point than the melting point of the fibers, the molten resin of a first fiber to a surface of the second fiber It is characterized by forming a nodular solid while adhering.

More specifically, two or more types of thermoplastic fibers having different melting points, or non-thermoplastic fibers and thermoplastic fibers are partially mixed, and a web is formed by a card machine 7.
The low-melting-point component is melted by heat treatment with the heater 9 to form bump-like irregularities composed of the low-melting-point fiber component (or the thermoplastic fiber component) on the high-melting-point fiber (or the non-thermoplastic fiber).

Further, another method for manufacturing a polishing sheet, card multiple synthetic Wei consisting of two or more components having different melting points
After forming into a web by a machine, or mixing a thermoplastic fiber comprising a low melting point component of the composite fiber with the composite fiber.
After forming the fibers into a web with a carding machine,
By performing a heat treatment at a temperature higher than the melting point of the point component and lower than the melting point of the high melting point component , the low melting point component is melted to form knob-like irregularities composed of the low melting point component on the high melting point fiber. Oh Ru. When a core-sheath fiber is used as the conjugate fiber, thermoplastic fibers of the same quality as the sheath component of the conjugate fiber are mixed in a conventional manner, and a fiber web is formed by a card machine 7. By heating at a temperature equal to or higher than the melting point of the thermoplastic resin of the portion and the fiber of the same quality as the resin and equal to or lower than the melting point of the core portion of the core-sheath structure, the sheath portion and the resin of the same quality are melted in the core-sheath structure. By adhering to the liquid, bump-like irregularities can be provided. Thereafter, in the case of a continuous sheet state, the sheet may be wound up in a roll shape, or may be continuously cut to a required length and folded and packaged as necessary.

[0023]

[Effect] The dirt that has adhered is polished due to the bump-like irregularities of the fiber surface layer, and then the dirt (polishing powder) polished off.
In the bulk of the nonwoven web. Further, since the fiber sheet is used, the sheet is bulky as a whole, so that the effect of collecting dirt between the constituent fibers of the sheet is high, and clogging of the polished portion can be suppressed to a minimum.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention will be described below in detail with reference to the drawings. In the polishing sheet 1 according to the embodiment of the present invention, countless solids 3 are fused to the fibers 2 constituting the surface of the sheet. The fibers constituting the surface are in the form of a bulky fibrous web and are designed to trap abrasive powder between the fibers.

Next, one embodiment of the method for producing a polishing sheet according to the present embodiment will be described. As shown in FIG. 3, the first fiber having a low melting point and the second fiber having a high melting point are mixed by a cotton mixing machine 5 and sent to a carding machine 7 by a feeding device 6, where a web is formed. The web is sent to a heating device 9 via a feeding device 8, and is subjected to a heat treatment. In this heating device 9, heating is performed at a temperature between the melting point of the first fiber and the melting point of the second fiber, and only the first fiber having a low melting point is melted to form a nodule in the second fiber. Stick. Then, when the web exits the heating device 9, the temperature applied to the fibers decreases, and the fibers melted in a nodular form solidify to form a nodular solid 3.

The web is further conveyed and wound up as a sheet roll 12 on a winder 11 via a nip roll 10 to obtain a polishing sheet 1 as shown in FIG. Example 1 Polypropylene / polyethylene (core / sheath) fiber 6 denier (polyethylene 50 wt%), 51 mm, polyethylene fiber 3 denier of the same quality as the sheath polyethylene, 51 mm 50 /
After mixing at a ratio of 50, a web was formed with a conventional card (basis weight 100 g / m ² ) to obtain a fiber web. Thereafter, heat treatment (condition: 150 ° C. × 15 seconds) is performed, and 20 cm × 2
It was cut to 0 cm to obtain a polishing sheet having bump-like irregularities as shown in FIGS.

Example 2 Polyester / polypropylene (core / sheath) fiber 6 denier (polypropylene 50 wt%), 51 mm, 3 denier polypropylene fiber of the same quality as the sheath polypropylene, and 51 mm were mixed at a weight ratio of 50/50, and a conventional card was used. To form a web (basis weight 100 g / m ² ) to obtain a fibrous web. After that, heat treatment (condition: 185 ° C. × 15 seconds) is performed, and 20 cm ×
It was cut to 20 cm to obtain a polishing sheet having bump-like irregularities as shown in FIGS.

Example 3 A polyester / polypropylene (core-sheath) fiber of 10 denier (75% by weight of polypropylene) and 51 mm was formed into a web (basis weight: 100 g / m ² ) using a conventional card to obtain a fiber web. Thereafter, a heat treatment (condition: 185 ° C. × 15 seconds) was performed, and the resultant was cut into 20 cm × 20 cm to obtain a polishing sheet having bump-like irregularities as shown in FIGS.

Comparative Example 1 A polypropylene / polyethylene (core-sheath) 6 denier (polyethylene 50 wt%), 51 mm, was formed into a web (basis weight 100 g / m ² ) by a conventional card to obtain a fiber web.
Thereafter, heat treatment (condition: 130 ° C. × 15 seconds) is performed,
The sheet was cut to a size of cm × 20 cm to obtain a sheet without bump-like irregularities.

Comparative Example 2 A polyester / polypropylene (core-sheath) fiber of 6 denier (polypropylene 50 wt%), 51 mm, was formed into a web (basis weight 100 g / m ² ) by a conventional card to obtain a fiber web. Thereafter, a heat treatment (condition: 165 ° C. × 15 seconds) was performed, and the sheet was cut into 20 cm × 20 cm to obtain a sheet without nodular irregularities.

Polishing Tests The following stains were produced, and the respective sheets according to the above-described Examples and Comparative Examples were tested for polishing ability and the like. Dirt A test piece of iron (3 cm × 8 cm) coated with 0.06 g of a rapeseed oil / carbon black (weight ratio: 5/1) mixture was denatured at 150 ° C. for 30 minutes to obtain a weakly modified dirt (pencil hardness 5B). Made and evaluated.

[0032]

[Table 1]

×: a problematic level ○: a level with almost no problem Δ: a level with a considerable problem ◎: a level with no problem As can be seen from this table, according to the present example, compared to the comparative example, Extremely excellent polishing effect, no clogging, no problem in terms of trapping, easy and sufficient removal of dirt without using an abrasive, and excellent performance as a polishing sheet You can see that.

[0034]

According to the method for producing a polishing sheet of the present invention ,
According to the manufactured polishing sheet, metals and the like can be easily and sufficiently polished without using an abrasive.
Furthermore, by polishing mainly the dirt adhered to the fixed surface with the projections and depressions of the fiber surface and trapping the dirt polished by the fibers constituting the nonwoven web, a wide range not available in the conventional polishing sheet. Dirt can be cleaned.

Further, since the polishing sheet of the present invention is a fibrous sheet, the cushioning property as a bulky sheet is improved, and the polishing sheet has a high ability to hold the polishing powder obtained by polishing off the fixed dirt. No need to rinse or wipe twice. According to the method for manufacturing a polishing sheet of the present invention, a uniform polishing sheet can be manufactured at high speed and in a stable manner.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a part of a polishing sheet according to the present invention cut out.

FIG. 2 is an enlarged view of the polishing sheet shown in FIG.

FIG. 3 is a drawing schematically showing a method of manufacturing the polishing sheet shown in FIG.

FIG. 4 is a perspective view showing a state of fibers before heat-treating the fibrous web of the polishing sheet of the present invention.

FIG. 5 is an enlarged view showing a fiber state shown in FIG. 4;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Polishing sheet 2 Fiber 3 Nodule solid 5 Cotton blender 7 Card machine 9 Heat treatment equipment

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) A47L 13/16-13/19 D04H 1/54-1/58

Claims (3)

(57) [Claims] 1. A first fiber having a low melting point and a second fiber having a high melting point are blended, and the blended fiber is formed into a web by a carding machine, and then the second fiber is heated to a temperature higher than the melting point of the first fiber. A method for manufacturing a polishing sheet, comprising heating at a temperature lower than the melting point of the first fiber and melting and bonding the resin made of the first fiber to the surface of the second fiber to form a nodular solid. 2. After forming a composite fiber comprising a low melting point component and a high melting point component on a web by a carding machine, heating at a temperature higher than the melting point of the low melting point component and lower than the melting point of the high melting point component, A method for producing a polishing sheet, comprising: melting a low-melting component on a high-melting component; and giving the high-melting component a bump-like unevenness. 3. The method for producing a polishing sheet according to claim 2 , wherein the web is obtained by mixing fibers comprising the low melting point component with the composite fibers.