JP6402018B2 - Nonwoven manufacturing method - Google Patents

Description

  The present invention relates to a method for producing a nonwoven fabric by processing a raised nonwoven fabric.

  The present applicant has previously proposed a method for producing a nonwoven fabric, in which a plurality of portions of the nonwoven fabric are partially stretched, and the nonwoven fabric subjected to the partial stretching processing is subjected to raising to raise the constituent fibers of the nonwoven fabric ( Patent Document 1).

  According to the method for producing a non-woven fabric described in Patent Document 1, a non-woven fabric having a raised feel of the constituent fibers is obtained, and a non-woven fabric with reduced reduction in the non-woven fabric breaking strength of the obtained raised non-woven fabric is obtained. Moreover, according to the manufacturing method of the nonwoven fabric of patent document 1, while raising the nonwoven fabric which raised the constituent fiber, manufacturing speed is quick and manufacturing cost can be held down.

  As another technique, Patent Document 2 discloses a paper dust removing roller that rotates so that the peripheral surface contacts the surface of the traveling paper, and paper dust that adheres to the peripheral surface of the paper dust removing roller. A paper dust removing device for paper that includes a cleaning means is described.

Japanese Patent No. 4882616 JP 2010-52835 A

  However, in the manufacturing method described in Patent Document 1, no attention has been paid to fibers that are likely to become fiber waste generated by performing partial stretching or raising. If fibers that can become fiber waste can be removed, contamination of the processing apparatus can be suppressed, and contamination of foreign matters into the product can be suppressed.

  According to the paper dust removing device described in Patent Document 2, paper dust attached to the paper can be removed. However, the paper dust removing device described in Patent Literature 2 is a device that removes paper dust from paper, and Patent Literature 2 describes nothing about a method for removing fibers that may become fiber waste of nonwoven fabric. It has not been.

  Therefore, this invention relates to providing the manufacturing method of the nonwoven fabric which can eliminate the said subject.

  The present invention is a method for producing a nonwoven fabric by raising a raw material nonwoven fabric in which a web containing long fibers is fixed by a heat-sealing part, and processing the raised nonwoven fabric with the long fibers raised, using an uneven roller for the raw material nonwoven fabric The raising process step of performing raising processing, the fiber recovery step of sucking and collecting fiber scraps that fall off from the raised nonwoven fabric using a fiber suction unit, and the raised nonwoven fabric from which the fiber scraps are recovered, A processing step of applying heat and / or external force to perform processing, wherein the fiber recovery step includes at least one static elimination unit disposed between the uneven roller and the fiber suction unit, and the fiber suction unit. And a convex roller for removing fibers that comes into contact with the processed surface that is raised by the uneven roller in the raised nonwoven fabric, and the convex roller for removing fibers has a height of the convex portion, Above There is provided a method of manufacturing a lower nonwoven fabric than the height of the convex portion of the convex roller.

  According to the manufacturing method of the nonwoven fabric of this invention, while being able to suppress the stain | pollution | contamination of a processing apparatus, mixing of the fiber waste to a product can be suppressed.

Drawing 1 is a mimetic diagram showing one embodiment of the suitable manufacturing device used for the manufacturing method of the nonwoven fabric of the present invention. FIG. 2 is a schematic diagram showing a concavo-convex roller included in the manufacturing apparatus shown in FIG. FIG. 3 is a schematic diagram showing a fiber removing convex roller provided in the manufacturing apparatus shown in FIG. 1. Fig.4 (a) is a partial expanded sectional view of the raw material nonwoven fabric used for the manufacturing method of the nonwoven fabric of this invention, FIG.4 (b) is a principal part expanded cross section which shows the state which has given the raising | fluff processing to the raw material nonwoven fabric Fig. 4 (c) is an enlarged cross-sectional view of a main part of the raised nonwoven fabric produced by raising the yarn. Drawing 5 is a mimetic diagram showing an uneven roller with which other manufacturing equipment used for a manufacturing method of a nonwoven fabric of the present invention is provided. FIG. 6A shows the amount of fiber waste collected by the fiber collection unit provided in the production apparatus when producing the nonwoven fabrics of Examples 1 and 2, and FIG. 6B shows the produced example. The quantity of the fiber waste collect | recovered in another fiber collection part with respect to the 1-2 nonwoven fabric is shown.

Hereinafter, the manufacturing method of the nonwoven fabric of this invention is demonstrated based on the preferable embodiment, referring FIGS.
FIG. 1 schematically shows an embodiment of a production apparatus (hereinafter also simply referred to as production apparatus) used in the method for producing a nonwoven fabric of the present invention.
Here, the Y direction in the figure means the direction in which the non-woven fabric in the MD direction along the orientation direction of the constituent fibers is conveyed, or the direction in which the sheet is conveyed by rotating the roller in the circumferential direction. Moreover, the X direction in the figure is a direction orthogonal to the Y direction, and means the roller rotation axis direction or the CD direction of the nonwoven fabric to be conveyed. In addition, the Z direction in the figure means a vertical direction that is a direction orthogonal to the surface direction composed of the Y direction and the X direction.

  As shown in FIG. 1, the manufacturing apparatus 100 of this embodiment is provided with the raising process part 2, the fiber collection | recovery part 3, and the process part 4 in this order toward the downstream from the upstream of the manufacturing process.

  The raised part 2 is a part for raising the nonwoven fabric 10 before processing (hereinafter also referred to as “raw material nonwoven fabric 10”). In the manufacturing apparatus 100 of the present embodiment, as shown in FIGS. In addition, a rotating roller, which is a concavo-convex roller 21 provided with a convex portion 211 on its peripheral surface, is provided. The uneven roller 21 is a rotating roller having a diameter of about 10 mm or more and 300 mm or less, and has a cylindrical shape made of metal such as aluminum alloy or steel. The concavo-convex roller 21 rotates when a driving force from a driving means (not shown) is transmitted to its rotating shaft. The rotational speed (circumferential speed V2) of the uneven roller 21 is controlled by a control unit (not shown) provided in the manufacturing apparatus 100. Here, the circumferential speed V <b> 2 of the uneven roller 21 means a speed on the surface of the convex portion 211 of the uneven roller 21.

  As shown in FIG. 1, the raised portion 2 includes transport rollers 22 and 23 that transport the raw material nonwoven fabric 10 on the upstream side and the downstream side of the uneven roller 21 (rotating roller). The conveyance rollers 22 and 23 are each arranged so as to come into contact with the surface of the raw material nonwoven fabric 10 opposite to the processing surface on which the raising process is performed. The conveyance speed V1 of the raw material nonwoven fabric 10 is controlled by a control unit (not shown) included in the manufacturing apparatus 100. Here, the conveyance speed V <b> 1 of the raw material nonwoven fabric 10 means a speed on the surface of the raw material nonwoven fabric 10 supplied to the uneven roller 21.

The uneven roller 21 can represent the height of the convex portion 211 by the arithmetic average roughness (Ra) of the roller surface measured according to ISO1997. The arithmetic average roughness (Ra) of the uneven roller 21 is preferably 1.5 μm or more, more preferably 10 μm or more, and more preferably 500 μm or less from the viewpoint of efficiently obtaining a raised nonwoven fabric with a large amount of raising. It is preferably 150 μm or less, specifically 1.5 μm or more and 500 μm or less, more preferably 10 μm or more and 150 μm or less.
The arithmetic average roughness (Ra) measured according to ISO 1997 is a value obtained by summing and averaging the absolute values of deviations from the average line to the evaluation curve.

The density of the convex portions 211 of the uneven roller 21 is preferably 500 pieces / cm ² or more, more preferably 1000 pieces / cm ² or more, from the viewpoint of efficiently obtaining a raised nonwoven fabric having a large amount of raising. And preferably 5000 pieces / cm ² or less, more preferably 3000 pieces / cm ² or less, specifically 500 pieces / cm ² or more and 5000 pieces / cm ² or less, More preferably, the number is 1000 / cm ² or more and 3000 / cm ² or less.

  The concavo-convex roller 21 having the surface as described above may be produced by subjecting the surface of a metallic cylindrical roller to sandblasting, or the surface of the metallic cylindrical roller subjected to sandblasting. Thereafter, the surface subjected to the sandblast treatment may be further polished. In the case of further polishing the surface subjected to the sandblasting treatment, the particle size based on the particle size definition of the abrasive for abrasive cloth paper of JIS R 6010 is determined from the viewpoint of smoothing by crushing the sharpened top. It is preferable to use sandpaper having a number of 50 or more and 1000 or less. However, this is not limited as long as the desired unevenness can be obtained, and rough machining by cutting may be used, or knurling may be used.

  The fiber recovery unit 3 is a part that recovers the fiber waste 1w that falls off the raised nonwoven fabric 1a that is manufactured by raising the raw material nonwoven fabric 10 using the uneven roller 21, and in the manufacturing apparatus 100 of the present embodiment. As shown in FIG. 1, the fiber suction part 31 that sucks the fiber waste 1 w, the static elimination part 32 arranged between the uneven roller 21 and the fiber suction part 31, and the fiber removal arranged in parallel with the fiber suction part 31 Convex roller 33 is provided.

  As shown in FIG. 1, the fiber suction unit 31 includes an air suction port 311 for sucking air. The air suction port 311 is disposed at a position facing the circumferential surface on the lower side in the Z direction of the fiber removing convex roller 33. The fiber suction portion 31 has an end opposite to the air suction port 311 connected to an air suction device (not shown). By operating the suction device (not shown), the air suction port 31 Air can be sucked from 311.

  The static elimination part 32 is a part which brings the charge amount of the raised nonwoven fabric 1a close to zero. As the static elimination part 32, the static elimination bar which contact | abuts to the raising nonwoven fabric 1a, or the ionizer which sprays the ionized air (it is also called air ion) to the raising nonwoven fabric 1a can be used. In the manufacturing apparatus 100, an ionizer is used. It is used. A commercially available static eliminator can be used as an ionizer that blows air ions. As the static eliminator, a type that blows air ions onto an object by blowing air or a soft X-ray that irradiates ions in the atmosphere. There are ionizing types. Examples of the type in which air ions are blown include a static elimination blower manufactured by Keyence Corporation, or a blower type direct current static elimination machine manufactured by Kasuga Electric Co., Ltd. Examples of the soft X-ray irradiation type include a photoionizer (light irradiation type static eliminator) manufactured by Hamamatsu Photonics Co., Ltd.

As shown in FIG. 1, the neutralization unit 32 is disposed in the vicinity of the first neutralization unit 321 disposed in the vicinity of the downstream side of the concavo-convex roller 21 and the downstream side of the convex roller 33 for removing fibers, as illustrated in FIG. 1. A second static elimination unit 322. Each of the first static elimination unit 321 and the second static elimination unit 322 is an ionizer that blows air ions as described above.
The 1st static elimination part 321 is distribute | arranged to the downstream of the raising nonwoven fabric 1a conveyance direction of the uneven | corrugated roller 21, and is arrange | positioned at the process surface 1p1 side which performed the raising process by the uneven | corrugated roller 21 in the raised nonwoven fabric 1a. Then, air ions are blown from the downstream side of the concavo-convex roller 21 to the peripheral surface of the concavo-convex roller 21 and the processed surface 1ap of the raised nonwoven fabric 1a by the first static elimination unit 321.

  As shown in FIG. 1, the second static elimination unit 322 is disposed on the downstream side of the fiber removal convex roller 33 in the conveying direction of the raised nonwoven fabric 1a and is in contact with the fiber removal convex roller 33 in the raised nonwoven fabric 1a. It is arranged on the 1p2 side. Then, air ions are sprayed from the downstream side of the fiber removal convex roller 33 to the peripheral surface of the fiber removal convex roller 33 and the processed surface 1p2 of the raised nonwoven fabric 1a by the second static elimination unit 322.

  As shown in FIG. 1, the fiber removing convex roller 33 is arranged in parallel with the fiber suction portion 31 and is in contact with the processing surface 1p1 subjected to raising by the uneven roller 21 in the raising nonwoven fabric 1a. The fiber removing convex roller 33 is a rotating roller having a diameter of about 10 mm to 300 mm, and has a metallic cylindrical shape such as an aluminum alloy or steel. The fiber removing convex roller 33 rotates when a driving force from a driving means (not shown) is transmitted to its rotating shaft. The rotational speed (circumferential speed V4) of the fiber removing convex roller 33 is controlled by a control unit (not shown) provided in the manufacturing apparatus 100. Here, the circumferential speed V4 of the fiber removing convex roller 33 means the speed on the surface of the convex portion 331 of the fiber removing convex roller 33.

  As shown in FIG. 1, the fiber recovery unit 3 includes transport rollers 34 and 35 that transport the raw material nonwoven fabric 10 on the upstream side and the downstream side of the fiber removal convex roller 33 (rotary roller). The conveyance rollers 34 and 35 are disposed so as to abut on the surface of the raw material nonwoven fabric 10 opposite to the processing surface on which the raising process is performed. The conveyance speed V3 of the raised nonwoven fabric 1a is controlled by a control unit (not shown) included in the manufacturing apparatus 100.

As shown in FIG. 3, the fiber removing convex roller 33 is formed such that the height of the convex portion 331 is lower than the height of the convex portion 211 of the concave-convex roller 21. The fiber removal convex roller 33 can represent the height of the convex part 331 by the arithmetic average roughness (Ra) of the roller surface measured according to ISO1997. The arithmetic average roughness (Ra) of the convex roller 33 for removing fibers is determined by the non-woven fabric in the later processing step without newly raising the non-woven fabric and being damaged by the fiber scraps adhering to the non-woven fabric or the uneven roller 21. From the viewpoint of reliably entwining the fibers that may be separated from the fiber and become fiber waste with the convex portion 331, it is preferably 0.1 μm or more, more preferably 0.2 μm or more, and It is preferably 5 μm or less, more preferably 1.0 μm or less, specifically preferably 0.1 μm or more and 1.5 μm or less, and preferably 0.2 μm or more and 1.0 μm or less. Further preferred.
The arithmetic average roughness (Ra) measured according to ISO 1997 is a value obtained by summing and averaging the absolute values of deviations from the average line to the evaluation curve.

The density of the convex portion 331 of the convex roller 33 for removing the fiber is such that the non-woven fabric is not newly brushed, and is separated from the non-woven fabric in a later processing step after being damaged by the fiber scraps attached to the non-woven fabric or the concave-convex roller 21 From the viewpoint of reliably entwining fibers that may become fiber waste with the convex portion 331, it is preferably higher than the density of the convex portions 211 of the concave-convex roller 21, and is 5,000 / cm ² or more. Is preferably 40,000 / cm ² or more, more preferably 100,000,000 / cm ² or less, and 1,000,000 / cm ² or less. More preferably, it is preferably 5,000 / cm ² or more and 100,000,000 / cm ² or less, more preferably 40,000 / cm ² or more and 1,000,000 / cm ^2. More preferably, it is as follows.

  The processing unit 4 is a part that applies heat and / or external force to the raised nonwoven fabric 1b formed by collecting the fiber waste 1w from the raised nonwoven fabric 1a to process it into a desired shape. As shown in FIG. 1, the processing unit 4 includes a coater-type die head 41 that applies an adhesive from a nozzle brought into contact with the raised nonwoven fabric 1 b in the manufacturing apparatus 100. The die head 41 is a member that applies an external force to the raised nonwoven fabric 1b in order to apply the adhesive while contacting the raised nonwoven fabric 1b. In addition to the die head 41, examples of the member that applies external force to the raised nonwoven fabric 1b include a direction changing bar that changes the conveying direction of the strip-like raised nonwoven fabric 1b, a sailor plate that folds the belt-like raised nonwoven fabric 1b, and the like. Examples of the member that applies heat to the raised nonwoven fabric 1b include a heat sealing device, an ultrasonic sealing device, a hot melt coating device, and hot air irradiation.

Next, an embodiment of the method for manufacturing a nonwoven fabric of the present invention will be described using the manufacturing apparatus 100 of the present embodiment described above with reference to FIGS.
The nonwoven fabric manufacturing method of the present invention uses a fiber suction portion 31 to collect and recover a raising process step of raising a raw material nonwoven fabric 10 using a concavo-convex roller 21 and a fiber scrap 1w that falls off the raised nonwoven fabric 1a. And a processing step of applying heat and / or external force to the raised nonwoven fabric 1b from which the fiber waste 1w has been recovered.

In this embodiment, first, as shown in FIG. 1, the strip-shaped raw material nonwoven fabric 10 which is a raw material is unwound from a roll (not shown) and conveyed. As shown in FIG. 4A, the raw material nonwoven fabric 10 is a nonwoven fabric formed by fixing a web including long fibers 11 with a heat-sealing portion 12. Preferable specific examples of the raw material nonwoven fabric 10 include a spunbond nonwoven fabric, a laminated nonwoven fabric of a spunbond layer and a meltblown layer, or a heat roller nonwoven fabric by a card method. Examples of the laminated nonwoven fabric include spunbond-spunbond laminated nonwoven fabric, spunbond-spunbond-spunbond laminated nonwoven fabric, spunbond-meltblown-spunbond laminated nonwoven fabric, spunbond-spunbond-meltblown-spunbond laminated nonwoven fabric, etc. Can be mentioned. The raw material nonwoven fabric 10 is inexpensive and has a good touch feeling, and from the viewpoint of processing suitability, the basis weight is preferably about 20 g / m ² , and is 8 g / m ² or more and 50 g / m ² or less. More preferably it is.

  It is preferable that the long fibers 11 constituting the raw material nonwoven fabric 10 mainly contain a thermoplastic resin. Examples of the thermoplastic resin include polyolefin resins, polyester resins, polyamide resins, acrylonitrile resins, vinyl resins, and vinylidene resins. Examples of the polyolefin resin include polyethylene, polypropylene, and polybuden. Examples of the polyester resin include polyethylene terephthalate and polybutylene terephthalate. Nylon etc. are mentioned as a polyamide-type resin. Examples of the vinyl resin include polyvinyl chloride. Examples of the vinylidene resin include polyvinylidene chloride. One of these various resins can be used alone or in admixture of two or more, and modified products of these various resins can also be used. Moreover, a composite fiber can also be used as the long fiber 11 constituting the raw material nonwoven fabric 10. Side-by-side fibers, core-sheath fibers, core-sheath fibers having eccentric crimps, split fibers, and the like can be used as the composite fibers. When using a composite fiber, it is preferable to use a core-sheath fiber whose core is made of polypropylene and whose sheath is made of polyethylene because a soft nonwoven fabric can be obtained. The fiber diameter of the long fiber 11 is preferably 5 μm or more and 30 μm or less, and more preferably 10 μm or more and 20 μm or less before processing described later.

The heat-sealed portion 12 constituting the raw material nonwoven fabric 10 preferably has a surface area of each heat-fused portion 12 of 0.05 mm ² or more and 10 mm ² or less from the viewpoint of touch and processing suitability, and 0.1 mm ^2. More preferably, it is 1 mm ² or less. The number of the heat-sealing parts 12 is preferably 10 pieces / cm ² or more and 250 pieces / cm ² or less, and more preferably 35 pieces / cm ² or more and 65 pieces / cm ² or less. The distance between the centers of the heat fusion parts 12 adjacent in the X direction is preferably 0.5 mm or more and 10 mm or less, more preferably 1 mm or more and 3 mm or less, and the heat fusion part adjacent in the Y direction. The distance between the centers of 12 is preferably 0.5 mm or more and 10 mm or less, and more preferably 1 mm or more and 3 mm or less.

  The heat-sealing part 12 was intermittently formed by thermocompression by embossing (by using an embossed convex roller and a flat roller), by ultrasonic welding, or intermittently hot-aired and partially fused. And the like. The shape of the heat fusion part 12 is not particularly limited, and may be any shape such as a circle, a rhombus, and a triangle in addition to the ellipse shown in FIG. The ratio of the total surface area of the heat-sealing part 12 to the surface area of one surface of the raw material nonwoven fabric 10 is preferably 5% or more and 30% or less, preferably 10% or more and 20% or less, from the viewpoint that it is difficult to produce pills. Is more preferable.

  Subsequently, the nonwoven fabric manufacturing method of this embodiment performs raising process using the uneven | corrugated roller 21 to the raw material nonwoven fabric 10 (raising process). In this embodiment, as shown in FIG. 1, the raw material nonwoven fabric 10 is transported by the transport rollers 22 and 23 to the concave and convex roller 21 in which the convex portions 211 are formed by subjecting the peripheral surface to sandblasting, and FIG. As shown in (b), the concavo-convex roller 21 raises the long fibers 11 constituting the raw material nonwoven fabric 10 from the surface of the raw material nonwoven fabric 10 to continuously produce the raised nonwoven fabric 1a.

  In the present embodiment, from the viewpoint of cutting the long fibers 11 which are constituent fibers of the raw material nonwoven fabric 10 from the boundary of the heat fusion part 12 and raising the hair efficiently from the surface of the raw material nonwoven fabric 10, The constituent fibers of the raw material nonwoven fabric 10 are raised using an uneven roller (rotating roller) 21 that rotates at a peripheral speed V2 different from the conveying speed V1 of the raw material nonwoven fabric 10. The rotation direction of the uneven roller 21 can be rotated in the reverse direction or the forward direction with respect to the conveying direction of the raw material nonwoven fabric 10, and from the viewpoint of efficiently raising the constituent fibers 11 of the raw material nonwoven fabric 10 from the surface of the raw material nonwoven fabric 10. It is preferable to rotate in the opposite direction. Thus, when rotating in the reverse direction, the value of the ratio (V2 / V1) of the circumferential speed V2 of the uneven roller 21 to the conveying speed V1 of the raw material nonwoven fabric 10 can sufficiently raise the surface of the raw material nonwoven fabric 10 into a roll. From the viewpoint of less fiber entanglement, it is preferably -10.0 or more, more preferably -5.0 or more, and preferably -0.3 or less, and -1.5 or less. More preferably, it is preferably -10.0 or more and -0.3 or less, and more preferably -5.0 or more and -1.5 or less. When the uneven roller 21 is not in the reverse direction but in the forward direction with respect to the conveying direction of the raw material nonwoven fabric 10, the ratio of the circumferential speed V2 of the uneven roller 21 to the conveying speed V1 of the raw material nonwoven fabric 10 (V2 / V1). Is preferably 1.1 or more, more preferably 2.0 or more, and preferably 20.0 or less, from the viewpoint of sufficiently raising the surface of the raw material nonwoven fabric 10. More preferably, it is 8.0 or less, specifically 1.1 or more and 20.0 or less, and more preferably 2.0 or more and 8.0 or less. Here, the negative value of (V2 / V1) means that the uneven roller 21 rotates in the opposite direction with respect to the conveying direction of the raised nonwoven fabric 1a.

  Further, an angle (hereinafter referred to as a holding angle) α (see FIG. 1) from when the raw material nonwoven fabric 10 starts to contact the peripheral surface of the uneven roller 21 until it leaves the peripheral surface of the uneven roller 21 as the raised nonwoven fabric 1a is the raw material. From the viewpoint of raising the surface of the nonwoven fabric 10 efficiently, it is preferably 10 ° or more, more preferably 30 ° or more, and preferably 180 ° or less, and further preferably 120 ° or less. Specifically, it is preferably 10 ° or more and 180 ° or less, and more preferably 30 ° or more and 120 ° or less.

Further, the conveyance tension of the raw material nonwoven fabric 10 to be conveyed can be adjusted according to the conveyance speed V1 of the raw material nonwoven fabric 10 and the positional relationship between the conveyance rollers 22 and 23 and the uneven roller 21, and the conveyance tension relaxes the raw material nonwoven fabric 10. It is preferably 10 N / m or more from the viewpoint of being able to convey without being pressed and preventing the raw nonwoven fabric 10 from being pressed too much against the uneven roller 21 which is a raised roll to make a hole or reduce the width of the raw nonwoven fabric 10, m or more, preferably 80 N / m or less, more preferably 40 N / m or less, and specifically 10 N / m or more and 80 N / m or less. More preferably, it is 20 N / m or more and 40 N / m or less. The conveyance tension of the raw material nonwoven fabric 10 can be measured in-line using a tension detector (for example, Mitsubishi Electric LX-TD type).

  As shown in FIG. 4 (c), the raised nonwoven fabric 1a manufactured in the raised processing step of the present embodiment includes fibers 11a having both ends fixed by a heat fusion part 12, and one end being thermally fused. The raised fiber 11b which is fixed by the attaching part 12 and the other end part is plastically deformed and is cut from the heat-fused part 12 and raised, and both end parts which become the fiber waste 1w are plastically deformed and the heat-fused part. The fiber 11c cut | disconnected from 12 and the fiber 11d with high possibility of becoming the fiber waste 1w are formed. As the fiber 11d having a high possibility of becoming the fiber waste 1w, one end portion is plastically deformed and thinned, the fiber is weakly fixed to the heat fusion portion 12, and the other end portion is cut from the heat fusion portion 12. Or the fiber etc. which the both ends are thin by plastic deformation, and are being fixed to the heat-fusion part 12 weakly are mentioned.

  Moreover, in the raising process of this embodiment, as shown in FIG. 1, it was distribute | arranged to the downstream of the raising nonwoven fabric 1a conveyance direction of the uneven | corrugated roller 21, and the raising process was given by the uneven | corrugated roller 21 in the raising nonwoven fabric 1a. Air ions are blown to the processed surface 1ap of the manufactured raised nonwoven fabric 1a by the first static elimination unit 321 arranged on the processed surface 1p1 side, and the charged amount of the raised nonwoven fabric 1a is brought close to zero.

  Next, the nonwoven fabric manufacturing method of the present embodiment sucks and collects the fiber waste 1w that falls off the raised nonwoven fabric 1a using the fiber suction part 31 (fiber recovery step). In this embodiment, the fiber waste 1w that falls off from the raised nonwoven fabric 1a is sucked and collected using the fiber suction part 31, and the raised nonwoven fabric 1b in which the fiber waste 1w is collected is continuously produced.

  Specifically, in this embodiment, as shown in FIG. 1, the raised nonwoven fabric 1 a subjected to the raising process is a fiber removing convex roller in which convex portions 331 are formed on the peripheral surface by conveying rollers 34 and 35. The fiber 11c having both ends cut from the heat-sealing part 12 is entangled on the peripheral surface of the fiber removing convex roller 33 as fiber waste 1w by the convex part 331. Further, the fiber 11d having a high possibility of becoming fiber waste 1w is cut from the thinned portion by plastic deformation by the convex portion 331, and the fiber 11d is cut into the peripheral surface of the fiber removing convex roller 33 as the fiber waste 1w. Entangled and caught.

  The rotation direction of the convex roller 33 for removing fibers can be rotated in the reverse direction or the normal direction with respect to the conveying direction of the raised nonwoven fabric 1a. In this embodiment, the convex roller for removing fibers is used as the fiber waste 1w. It is preferable to rotate in the reverse direction from the viewpoint of efficiently entangled with the circumferential surface of 33. In this embodiment, the conveyance speed V3 of the raised nonwoven fabric 1a is the same as the conveyance speed V1 of the raw material nonwoven fabric 10. The ratio (V4 / V3, V4 / V1) of the circumferential speed V4 of the fiber removing convex roller 33 to the conveying speed V3 of the raised nonwoven fabric 1a (conveying speed V1 of the raw nonwoven fabric 10) is sufficient for the fiber waste 1w and the fibers 11d. From the viewpoint of generating no further raising while being entangled with the convex portion 331, it is preferably −0.2 or more, more preferably −0.01 or more, based on the conveyance direction of the raised nonwoven fabric 1a. It is preferably 0 or less, more preferably −0.001 or less, specifically preferably −0.2 or more and 0 or less, and −0.01 or more and −0. More preferably, it is 001 or less. Here, a negative value of (V4 / V3, V4 / V1) means that the fiber removal convex roller 33 is rotating in the opposite direction with respect to the conveying direction of the raised nonwoven fabric 1a.

  Further, an angle (hereinafter referred to as a holding angle) β (refer to FIG. 1) from when the raised nonwoven fabric 1a starts to contact the peripheral surface of the convex roller 33 for removing fibers to the peripheral surface is referred to as the fiber waste 1w and the fibers 11d. From the viewpoint of not generating further brushing while being sufficiently entangled with the convex portion 331, it is preferably 10 ° or more, more preferably 180 ° or more, and preferably 15 ° or less, More preferably, it is 40 ° or less, specifically 10 ° or more and 180 ° or less, and more preferably 15 ° or more and 40 ° or less.

Further, the conveying tension of the raised nonwoven fabric 1a to be conveyed can be adjusted by the conveying speed V3 of the raised nonwoven fabric 1a and the positional relationship between the conveying rollers 34 and 35 and the convex roller 33 for fiber removal. 1a can be transported without loosening, and from the viewpoint of preventing the convex roller 33 for removing fibers from becoming a transport resistance and shrinking in width, it is preferable to use the same transport tension as that of the raw material nonwoven fabric 10, and more specifically 10N / m or more, preferably 20 N / m or more, more preferably 80 N / m or less, still more preferably 40 N / m or less, specifically 10 N / m. It is preferably 80 N / m or less, more preferably 20 N / m or more and 40 N / m or less. The conveyance tension of the raised nonwoven fabric 1a can be measured inline using a tension detector (for example, Mitsubishi Electric LX-TD type) in the same manner as the conveyance tension of the raw material nonwoven fabric 10 described above.

  In the fiber recovery process of this embodiment, as shown in FIG. 1, the fiber removal convex roller 33 is arranged on the downstream side in the conveying direction of the raised nonwoven fabric 1a and abuts against the fiber removal convex roller 33 in the raised nonwoven fabric 1a. Air ions are blown against the peripheral surface of the convex roller 33 for removing fibers and the processed surface 1p2 of the raised nonwoven fabric 1a by the second static eliminating portion 322 arranged on the processed surface 1p2 side. The charge amount of the circumferential surface 33 and the raised nonwoven fabric 1a is brought close to zero.

  And in the fiber collection process of this embodiment, as shown in FIG. 1, it is for fiber removal by the fiber suction part 31 arrange | positioned in the position facing the circumferential surface of the Z direction lower side of the convex roller 33 for fiber removal. The fibers 11c and 11d entangled around the peripheral surface of the convex roller 33, and the fibers 11c remaining on the processed surface 1p2 of the raised nonwoven fabric 1a are sucked and collected as fiber waste 1w from the air suction port 311. As described above, the raised nonwoven fabric 1b in which the fiber waste 1w is collected is continuously manufactured.

  The suction force from the air suction port 311 by the fiber suction part 31 is preferably a gauge pressure, preferably 0.1 kPa or more, more preferably from the viewpoint of reliably collecting the fiber waste 11w entangled with the fiber removal convex roll 33 It is 0.5 kPa or more, and preferably 20 Pa or less, more preferably 10 kPa or less. Specifically, it is preferably 0.1 Pa or more and 20 kPa or less, more preferably 0.5 kPa or more and 10 kPa or less.

  Next, in the method for manufacturing the nonwoven fabric of this embodiment, heat and / or external force is applied to the raised nonwoven fabric 1b from which the fiber waste 1w has been collected (processing step). In this embodiment, as shown in FIG. 1, a coater type die head 41 is brought into contact with the raised nonwoven fabric 1b, and an adhesive is applied to the raised nonwoven fabric 1b while applying an external force by contact. The brushed nonwoven fabric 1b coated with an adhesive is used as, for example, a surface sheet for an absorbent article, a back sheet, a sheet constituting an outer packaging material of a disposable diaper, etc., and absorbs mainly a disposable diaper, a sanitary napkin, or the like. Processed into articles. Moreover, the raised nonwoven fabric 1b coated with the adhesive is used, for example, as a cleaning surface sheet of a cleaning sheet, and is processed into a cleaning sheet.

  According to the manufacturing method of the nonwoven fabric of the present embodiment described above, since the fiber scrap 1w that drops off from the raised nonwoven fabric 1a is sucked and collected using the fiber suction portion 31, both ends are heated. Not only the fiber 11c cut from the fusion | bond part 12 but the fiber 11d with high possibility of becoming fiber waste 1w can be collect | recovered as fiber waste 1w. Therefore, it is possible to suppress the contamination of the processing apparatus such as the die head 41 that contacts the raised nonwoven fabric 1b, and to suppress the mixing of the fiber waste 1w that can be a foreign matter into a product such as an absorbent article or a cleaning sheet. it can. According to the method for producing a nonwoven fabric of this embodiment, the raised nonwoven fabric 1b with improved quality can be produced efficiently and continuously.

  Further, according to the method for manufacturing a nonwoven fabric of this embodiment, as shown in FIG. 1, in the vicinity of the downstream side of the first neutralization unit 321 disposed in the vicinity of the downstream side of the uneven roller 21 and the convex roller 33 for removing fibers. Since neutralization is performed by the second neutralization unit 322 disposed, it is possible to further suppress contamination of the processing apparatus and to further suppress the mixing of the fiber waste 1w that can be a foreign substance into the product. In particular, according to the method for manufacturing a nonwoven fabric of this embodiment, the first static elimination unit 321 is arranged on the downstream side in the conveying direction of the raised nonwoven fabric 1a of the uneven roller 21 and is subjected to raising by the uneven roller 21 in the raised nonwoven fabric 1a. Is disposed on the processed surface 1p1 side, and the second charge eliminating portion 322 is disposed on the downstream side in the conveying direction of the raised nonwoven fabric 1a of the fiber removing convex roller 33, and the convex roller for removing fiber in the raised nonwoven fabric 1a. Since it is arranged on the processing surface 1p2 side in contact with 33, it is possible to further suppress contamination of the processing apparatus and to further suppress the mixing of the fiber waste 1w that can be a foreign matter into the product.

  The manufacturing method of the nonwoven fabric of this invention is not restrict | limited at all to the manufacturing method of the above-mentioned embodiment, It can change suitably.

  For example, in the method for manufacturing the nonwoven fabric of the above-described embodiment, as shown in FIGS. 1 and 2, the uneven roller 21 is used in the raising process, but instead of the uneven roller 21, as shown in FIG. 5. A steel matching embossing roller 26 composed of a pair of uneven rollers 24 and 25 may be used. The steel matching embossing roller 26 is of a metallic cylindrical shape such as aluminum alloy or steel, and has one convex / concave roller 24 having a plurality of convex portions 241 that are uniformly distributed on the peripheral surface, and the other concave / convex roller. 25 has a concave portion 252 into which the convex portion 241 enters at a position corresponding to the convex portion 241 of the one concave-convex roller 24 on the peripheral surface. In addition, the other concavo-convex roller 25 has a plurality of convex portions 251 that are uniformly distributed on the peripheral surface, and one concavo-convex roller 24 protrudes at a position corresponding to the convex portion 251 of the other concavo-convex roller 25 on the peripheral surface. It has a recess 242 into which the part 251 enters. The pair of concavo-convex rollers 24 and 25 are rotating rollers having a diameter of about 50 mm or more and 300 mm or less, and are engaged with each other and rotated by transmitting a driving force from a driving means (not shown) to at least one rotating shaft. As a material of the steel matching embossing roller 26, resin or the like can be used in addition to the above-mentioned metal, but it is preferably made of metal from the viewpoint of antistatic. In the steel matching embossing roller 26, one uneven roller 24 and the other uneven roller 25 are the same roller except that the convex portions 241 and 251 are provided at positions corresponding to the concave portions 252 and 242, respectively. is there. Therefore, in the following description, the convex portion 241 of one of the concave and convex rollers 24 will be mainly described for similar portions.

  Each convex portion 241 of the concave / convex roller 24 has a height from the bottom of the concave / convex roller 24 to the apex of the convex portion 241 of preferably 1 mm or more and 10 mm or less, and more preferably 2 mm or more and 7 mm or less. The distance (pitch) between the protrusions 241 adjacent in the rotation axis direction (X direction) is preferably 0.01 mm or more and 20 mm or less, more preferably 1 mm or more and 10 mm or less, and protrusions adjacent in the circumferential direction. The distance (pitch) between the portions 241 is preferably 0.01 mm or more and 20 mm or less, and more preferably 1 mm or more and 10 mm or less. The shape of the top surface of each convex portion 241 of the uneven roller 24 is not particularly limited, but the steel matching embossing roller 26 is formed in a circular shape. The depth of engagement between the convex portions 241 of the concave-convex roller 24 and the convex portions 251 of the concave-convex roller 25 (the length of the portion where the convex portions 241 and the convex portions 251 overlap) is 0.1 mm or more. Preferably, it is 1 mm or more, more preferably 10 mm or less, and further preferably 8 mm or less. Specifically, it is preferably 0.1 mm or more and 10 mm or less, and more preferably 1 mm or more and 8 mm or less.

  The steel matching embossing roller 26 rotates in the direction shown in FIG. In the raising process using the steel matching embossing roller 26 shown in FIG. 5, the raw material nonwoven fabric 10 is transported between the pair of uneven rollers 24 and 25 by the transport rollers 22 and 23, and the raw material nonwoven fabric 10 is partially stretched. Be sure to apply brushing. More specifically, the conveyed raw material nonwoven fabric 10 is sandwiched between a plurality of convex portions 241 of one concave-convex roller 24 and a plurality of concave portions 252 of the other concave-convex roller 25, and the other The conveyance direction and the direction orthogonal to the conveyance direction are respectively sandwiched between the plurality of convex portions 251 of the concave / convex roller 25 and the plurality of concave portions 242 of the one concave / convex roller 24. Brushing is performed while stretching is applied.

  Moreover, in the manufacturing method of the nonwoven fabric of the above-mentioned embodiment, as shown in FIG. 1, although the static elimination is carried out using the two static elimination parts 32 of the 1st static elimination part 321 and the 2nd static elimination part 322, an uneven roller The neutralization may be performed by using at least one neutralization unit 32 disposed between the fiber 21 and the fiber suction unit 31. Moreover, the 1st static elimination part 321 is distribute | arranged to the downstream side of the raising nonwoven fabric 1a conveyance direction of the uneven | corrugated roller 21 as shown in FIG. 1, and the process surface 1p1 side which gave the raising process by the uneven roller 21 in the raised nonwoven fabric 1a However, it may be disposed on the non-processed surface side, or may be disposed directly above the uneven roller 21 in the Z direction. Moreover, the 2nd static elimination part 322 is distribute | arranged to the downstream side of the raising nonwoven fabric 1a conveyance direction of the raised fiber nonwoven fabric 1a as shown in FIG. 1, and contact | abutted to the raised roller 33 for fiber removal in the raised nonwoven fabric 1a Although it arrange | positions at the process surface 1p2 side, you may arrange | position at the non-process surface side.

  Moreover, you may give a small amount of additives, such as an antistatic property agent, a lubricant, and a hydrophilic agent, to the fiber which comprises the raw material nonwoven fabric 10. FIG.

  Further, a feed roll or a free roll for controlling the tension of the raised nonwoven fabric 1a may be disposed between the uneven roller 21 and the fiber removing convex roller 33. In this case, each roll is arranged so as to be placed on the raised nonwoven fabric 1a on the surface opposite to the surface on which the raised nonwoven fabric 1a is raised, thereby preventing the fiber waste 1w from adhering to and accumulating on each roll. It is preferable to do.

  The following non-woven fabric manufacturing method is disclosed with respect to the embodiment described above.

<1>
A method for producing a nonwoven fabric by raising a raw material nonwoven fabric in which a web containing long fibers is fixed by a heat fusion part, and processing the raised nonwoven fabric in which the long fibers are raised,
A raising process step of raising the raw material nonwoven fabric using an uneven roller,
A fiber recovery process for sucking and recovering fiber scraps that fall off from the raised nonwoven fabric using a fiber suction part;
A processing step of applying heat and / or external force to the raised nonwoven fabric from which the fiber waste has been collected,
In the fiber recovery step, at least one static elimination unit disposed between the uneven roller and the fiber suction unit, and a raising process is performed by the uneven roller in the raised nonwoven fabric arranged in parallel with the fiber suction unit. Using a convex roller for removing fibers in contact with the processed surface,
The convex roller for removing fibers is a method for producing a nonwoven fabric in which the height of the convex portion is lower than the height of the convex portion of the concave-convex roller.

<2>
The said neutralization part is a manufacturing method of the nonwoven fabric as described in said <1> which is an ionizer which sprays an air ion.
<3>
The fiber removal convex roller has a ratio (V4 / V3) of a circumferential speed (V4) of the fiber removal convex roller to a conveyance speed (V3) of the raised nonwoven fabric, based on the conveyance direction of the raised nonwoven fabric. -The manufacturing method of the nonwoven fabric as described in said <1> or <2> which is 0.2 or more and 0 or less.
<4>
The fiber removal convex roller has a ratio (V4 / V3) of a circumferential speed (V4) of the fiber removal convex roller to a conveyance speed (V3) of the raised nonwoven fabric, based on the conveyance direction of the raised nonwoven fabric. -0.2 or more, preferably -0.01 or more, and 0 or less, preferably -0.001 or less, specifically -0.2 or more and 0 or less, preferably -0.01 or more and -0. The manufacturing method of the nonwoven fabric as described in said <3> which is 001 or less.
<5>
The said uneven roller is a manufacturing method of the nonwoven fabric any one of said <1>-<4> rotated in a reverse direction with respect to the conveyance direction of the said raw material nonwoven fabric.
<6>
The nonwoven fabric according to any one of <1> to <5>, wherein the convex roller for removing fibers has an arithmetic average roughness of a roller surface measured in accordance with ISO1997 of 0.1 μm or more and 1.0 μm or less. Manufacturing method.
<7>
The convex roller for removing fibers has an arithmetic average roughness of the roller surface measured according to ISO 1997 of 0.1 μm or more, preferably 0.2 μm or more, and 1.5 μm or less, preferably 1.0 μm or less, Specifically, the method for producing a nonwoven fabric according to the above <6>, which is 0.1 μm or more and 1.5 μm or less, preferably 0.2 μm or more and 1.0 μm or less.
<8>
The neutralization unit includes a first neutralization unit disposed in the vicinity of the downstream side of the uneven roller, and a second neutralization unit disposed in the vicinity of the downstream side of the convex roller for removing fibers. The manufacturing method of the nonwoven fabric any one of>-<7>.
<9>
Said 1st static elimination part is a manufacturing method of the nonwoven fabric as described in said <8> arrange | positioned at the process surface side which gave the raising process by the uneven | corrugated roller in the said raised nonwoven fabric.
<10>
<8> or <9> according to <8> or <9>, in which air ions are blown from the downstream side of the uneven roller to the peripheral surface of the uneven roller and the processed surface of the brushed nonwoven fabric by the first static elimination unit. Nonwoven fabric manufacturing method.
<11>
The said 2nd static elimination part is a manufacturing method of the nonwoven fabric any one of said <8>-<10> arrange | positioned at the process surface side contact | abutted to the said convex roller for fiber removal in the said raised nonwoven fabric.
<12>
<8> to <8>, in which air ions are sprayed from the downstream side of the fiber removal convex roller to the peripheral surface of the fiber removal convex roller and the processed surface of the brushed nonwoven fabric by the second static elimination unit. The manufacturing method of the nonwoven fabric any one of <11>.

<13>
The density of the convex part of the said convex roller for fiber removal is a manufacturing method of the nonwoven fabric any one of said <1>-<12> higher than the density of the convex part of the said uneven roller.
<14>
The density of the convex portions of the convex roller for removing fibers is preferably 5,000 pieces / cm ² or more, preferably 40,000 pieces / cm ² or more, and 100,000,000 pieces / cm ² or less. , Preferably 1,000,000 pieces / cm ² or less, specifically 5,000 pieces / cm ² or more and 100,000,000 pieces / cm ² or less, preferably 40,000 pieces / cm ² or more 1, the 000,000 pieces / cm ² or less <1> to <13> the method for producing non-woven fabric according to any one of.
<15>
The said processing process is a manufacturing method of the nonwoven fabric any one of said <1>-<14> performed using the coater type die head which coats an adhesive agent from the nozzle contacted with the said raising nonwoven fabric.
<16>
The ratio (V2 / V1) of the circumferential speed (V2) of the uneven roller to the conveyance speed (V1) of the raw material nonwoven fabric is −10.0 or more, preferably −5. 0 or more and -0.3 or less, preferably -1.5 or less, specifically -10.0 or more and -0.3 or less, preferably -5.0 or more and -1.5 or less. The manufacturing method of the nonwoven fabric any one of <1>-<15>.
<17>
The ratio (V2 / V1) of the circumferential speed (V2) of the uneven roller to the conveying speed (V1) of the raw material nonwoven fabric is 1.1 or more, preferably 2.0 or more based on the conveying direction of the raw material nonwoven fabric. And <2> or less, preferably 8.0 or less, specifically 1.1 or more and 20.0 or less, preferably 2.0 or more and 8.0 or less. The manufacturing method of the nonwoven fabric any one.
<18>
The angle from when the raised nonwoven fabric begins to contact the circumferential surface of the convex roller for removing fibers to the distance from the circumferential surface is 10 ° or more, preferably 180 ° or more, and 15 ° or less, preferably 40 ° or less. The method for producing a nonwoven fabric according to any one of the above items <1> to <17>, which is 10 ° to 180 °, preferably 15 ° to 40 °.
<19>
The method for producing a nonwoven fabric according to any one of <1> to <18>, wherein the convex roller for removing fibers is a rotating roller having a diameter of 10 mm to 300 mm.
<20>
The method for producing a nonwoven fabric according to any one of <1> to <19>, wherein the uneven roller is a rotating roller having a diameter of 10 mm to 300 mm.
<21>
The uneven roller has an arithmetic average roughness of the roller surface measured according to ISO 1997 of 1.5 μm or more, preferably 10 μm or more, and 500 μm or less, preferably 150 μm or less, specifically, 1.5 μm or more. The method for producing a nonwoven fabric according to any one of <1> to <20>, which is 500 μm or less, preferably 10 μm or more and 150 μm or less.
<22>
The density of the convex portions of the concave-convex roller is 500 pieces / cm ² or more, preferably 1000 pieces / cm ² or more, and 5000 pieces / cm ² or less, preferably 3000 pieces / cm ² or less, specifically 500 pieces / cm ^2. The method for producing a nonwoven fabric according to any one of <1> to <21>, wherein the number is from 1 piece / cm ^{2 to} 5000 pieces / cm ² , preferably from 1000 pieces / cm ^{2 to} 3000 pieces / cm ² .
<23>
The method for producing a nonwoven fabric according to any one of <1> to <22>, wherein the basis weight of the raw material nonwoven fabric is 8 g / m ² or more and 50 g / m ² or less.

<24>
A nonwoven fabric manufacturing apparatus for raising a raw material nonwoven fabric in which a web containing long fibers is fixed by a heat fusion part, and processing the raised nonwoven fabric in which the long fibers are raised,
Raising processing part which performs raising processing using an uneven roller on the raw material nonwoven fabric,
A fiber recovery part that sucks and recovers fiber scraps that fall off from the raised nonwoven fabric using a fiber suction part, and
A processing unit that applies heat and / or external force to the raised nonwoven fabric from which the fiber waste has been collected,
The fiber recovery unit is brushed by the uneven roller in the raised nonwoven fabric and at least one neutralizing unit disposed between the uneven roller and the fiber suction unit, and disposed in parallel with the fiber suction unit. A convex roller for fiber removal that comes into contact with the processed surface,
The fiber removing convex roller is a nonwoven fabric manufacturing apparatus in which the height of the convex portion is lower than the height of the convex portion of the concave-convex roller.

<25>
The said raising process part is a manufacturing apparatus of the nonwoven fabric as described in said <24> provided with the 1st conveyance roller which conveys the said raw material nonwoven fabric to the upstream and downstream of the said uneven | corrugated roller.
<26>
The said fiber collection | recovery part is a manufacturing apparatus of the nonwoven fabric as described in said <24> or <25> provided with the 2nd conveyance roller which conveys the said raw material nonwoven fabric in the upstream and downstream of the said convex roller for fiber removal.
<27>
Said 1st conveyance roller and 2nd conveyance roller are arrange | positioned so that it may contact | abut on the surface on the opposite side to the process surface in which the said raising | fluff process is given in the said raw material nonwoven fabric. Non-woven fabric manufacturing equipment.
<28>
The said process part is a manufacturing apparatus of the nonwoven fabric any one of said <24>-<27> provided with the coater type die head which applies an adhesive agent from the nozzle contacted with the said raising nonwoven fabric.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the scope of the present invention is not limited to such examples.

[Example 1]
As the raw material nonwoven fabric, a spunbonded nonwoven fabric having a basis weight of 17 g / m ^{2 made} of polypropylene resin having a fiber diameter of 10 μm was used. Further, the heat-sealed portion constituting the raw material nonwoven fabric had a surface area of 0.09 mm ² per piece, and the number thereof was 25 pieces / cm ² . Next, the spunbond nonwoven fabric was passed through the manufacturing apparatus 100 shown in FIG. 1 to produce the nonwoven fabric of Example 1. Regarding the uneven roller 21, the diameter was 100 mm, the arithmetic average roughness (Ra) was 13.9 μm, and the density of the convex portions was 3,000 / cm ² . Further, regarding the convex roller 33 for removing fibers, the diameter was 25 mm, the arithmetic average roughness (Ra) was 0.33 μm, and the density of the convex portions was 92,000 / cm ² . Moreover, the value of the ratio (V2 / V1) of the circumferential speed V2 of the uneven roller to the conveying speed V1 of the raw material nonwoven fabric was −1.6. Further, the ratio (V4 / V3) of the circumferential speed V4 of the convex roller for removing fibers to the conveying speed V3 of the raised nonwoven fabric was -0.0015. The holding angle β to the convex roller for removing fibers was 20 °, and the conveying tension of the raised nonwoven fabric was 25 N / m or more. Moreover, the suction force of the fiber suction part was 0.7 kPa.

[Example 2]
The same raw material nonwoven fabric as in Example 1 was used, and the nonwoven fabric of Example 2 was produced under the same conditions as in Example 1 except for the conditions related to the convex roller 33 for fiber removal. Specifically, regarding the fiber removing convex roller 33, the diameter was 25 mm, the arithmetic average roughness (Ra) was 0.83 μm, and the density of the convex portions was 80,000 pieces / cm ² . Further, the ratio (V4 / V3) of the peripheral speed V4 of the convex roller for removing fibers to the conveying speed V3 of the raised nonwoven fabric was -0.0015. The holding angle β to the convex roller for removing fibers was 180 °, and the conveying tension of the raised nonwoven fabric was 50 N / m or more.

[Performance evaluation]
About the nonwoven fabric of Examples 1-2, the fiber waste generation amount attracted | sucked by the fiber suction part 31 was calculated | required, and it showed to Fig.6 (a). Moreover, in the manufacturing apparatus 100 shown in FIG. 1, another fiber suction part is arrange | positioned between the fiber collection | recovery part 3 and the process part 4, and the fiber waste generation amount attracted | sucked by another fiber suction part is calculated | required, This is shown in FIG. In addition, the suction force of another fiber suction part was 6.8 kPa.

  Although the suction force of another fiber suction part is nearly 10 times the suction force of the fiber suction part 31, as shown in FIG. 6 (a) and FIG. 6 (b), in another fiber suction part. The amount of fiber waste generated is greatly reduced compared to the amount of fiber waste generated in the fiber suction part 31. Moreover, as a comparative example, the fiber waste generation amount when only another fiber suction part was arranged without using the fiber recovery part 3 was 63 mg, which was increased as compared with Examples 1-2. As is clear from this, the nonwoven fabrics of Examples 1 and 2 include fibers that are likely to become fiber waste by the fiber recovery unit 3 included in the manufacturing apparatus 100 shown in FIG. It was found that it could be recovered. Therefore, according to the nonwoven fabric manufacturing method using the manufacturing apparatus 100 shown in FIG. 1, it can be expected that the processing apparatus such as a die head that discharges the adhesive is prevented from being contaminated, and the fiber waste is prevented from being mixed into the product. I can expect.

DESCRIPTION OF SYMBOLS 100 Manufacturing apparatus 10 Raw material nonwoven fabric 1a, 1b Brushed nonwoven fabric 1w Fiber waste 11 Long fiber 12 Heat-bonding part 2 Brushed part 21 Concave roller 211 Convex part 22, 23 Conveyance roller 24, 25 Concave roller 26 Steel matching emboss roller 241,251 Convex part 242, 252 Concave part 3 Static elimination part 31 Fiber suction part 32 Static elimination part 321 First static elimination part 322 Second static elimination part 33 Convex roller for fiber removal 331 Convex part 34, 35 Conveying roller 4 Processing part 41 Die head

Claims (5)

A method for producing a nonwoven fabric by raising a raw material nonwoven fabric in which a web containing long fibers is fixed by a heat fusion part, and processing the raised nonwoven fabric in which the long fibers are raised,
A raising process step of raising the raw material nonwoven fabric using an uneven roller,
A fiber recovery process for sucking and recovering fiber scraps that fall off from the raised nonwoven fabric using a fiber suction part;
A processing step of applying heat and / or external force to the raised nonwoven fabric from which the fiber waste has been collected,
In the fiber recovery step, at least one static elimination unit disposed between the uneven roller and the fiber suction unit, and a raising process is performed by the uneven roller in the raised nonwoven fabric arranged in parallel with the fiber suction unit. Using a convex roller for removing fibers in contact with the processed surface,
The convex roller for removing fibers is a method for producing a nonwoven fabric in which the height of the convex portion is lower than the height of the convex portion of the concave-convex roller.   The fiber removal convex roller has a ratio (V4 / V3) of a circumferential speed (V4) of the fiber removal convex roller to a conveyance speed (V3) of the raised nonwoven fabric, based on the conveyance direction of the raised nonwoven fabric. The method for producing a nonwoven fabric according to claim 1, which is −0.2 or more and 0 or less.   The said uneven roller is a manufacturing method of the nonwoven fabric of Claim 1 or 2 rotated in a reverse direction with respect to the conveyance direction of the said raw material nonwoven fabric.   The nonwoven fabric production according to any one of claims 1 to 3, wherein the convex roller for removing fibers has an arithmetic average roughness of a roller surface measured in accordance with ISO 1997 of 0.1 µm or more and 1.0 µm or less. Method.   The said static elimination part has the 1st static elimination part distribute | arranged to the downstream vicinity of the said uneven | corrugated roller, and the 2nd static elimination part distribute | arranged to the downstream vicinity of the said convex roller for fiber removal further. The manufacturing method of the nonwoven fabric of any one of -4.

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