JP6464487B2 - Laminate manufacturing method and manufacturing apparatus - Google Patents

Description

  The present invention relates to a manufacturing method and a manufacturing apparatus for a laminate, and relates to a method and an apparatus for stacking a plurality of sheets using an adhesive.

  A laminated body in which a plurality of sheets are laminated has high strength and is used for various purposes. For example, patent document 1 uses the laminated body provided with the nonwoven fabric which is a base material, the other nonwoven fabric as a protective layer, and the ultrafine fiber layer interposed between these as filter media, such as an air cleaner. Has proposed. In such a laminate, for example, ultrafine fibers are deposited on a nonwoven fabric (first sheet) as a base material by an electrospinning method or the like, and then an adhesive is applied, and another nonwoven fabric (second sheet) is used as a protective layer. ) Are laminated.

JP 2014-121699 A

  However, if the adhesive is applied unevenly to the laminate, peeling occurs between the sheets. In the case of a laminate having air permeability, pressure loss may increase.

One aspect of the present invention is that the raw material resin is prepared from a raw material solution that includes a preparation step of preparing the first sheet and the second sheet, and a raw material resin that is a raw material of the fiber and a solvent that dissolves the raw material resin by an electrospinning method. to produce the fibers containing, said fibers, said first electrospinning depositing on one main surface of the sheet, to the main surface of the first sheet of the fibers are deposited, over the main surface An adhesive spraying step of spraying adhesive particles, and a laminating step of laminating the second sheet on the first sheet via the adhesive, with the spraying device disposed in A spraying device includes a storage portion that stores the adhesive and includes an opening that faces the main surface, and a roller that is fitted into the opening so that a first gap is formed. Has a groove on the outer peripheral surface The storage section includes a control plate disposed so as to cross the inside, and the control plate passes through the storage section with a first region on the opening side and a second region other than the first region. The first region and the second region are communicated with each other through a communication port, and the adhesive stored in the second region is supplied from the communication port to the first region. In the first region, the adhesive supplied from the communication port is deposited on the outer peripheral surface of the roller located on the opposite side of the main surface of the first sheet, and the adhesive spraying step includes: It is related with the manufacturing method of a laminated body which rotates the said roller and spreads the said adhesive agent with which the said groove | channel of the said outer peripheral surface of the said roller was sprinkled on the said main surface from the said 1st clearance gap.

In another aspect of the present invention, the fiber containing the raw material resin is generated from a raw material liquid containing a raw material resin that is a raw material of the fiber and a solvent that dissolves the raw material resin, and the fiber is one of the first sheets. An electrospinning part to be deposited on the main surface, an adhesive sprinkling part that is disposed downstream of the electrospinning part and sprays adhesive particles on one main surface of the first sheet, and the adhesive It is arrange | positioned downstream of the spreading | diffusion part, It comprises the lamination | stacking part which laminates | stacks a 2nd sheet | seat on the said 1st sheet via the said adhesive agent, The said adhesive spreading part stores the said adhesive agent. And a spraying device comprising a storage portion having an opening facing the main surface and a roller fitted in the opening so that a first gap is formed, wherein the roller has a groove on the outer peripheral surface. And the storage part is arranged so as to cross the inside. The control plate divides the interior of the reservoir into a first region on the opening side and a second region other than the first region, and the first region and the The second region communicates with a communication port, and the adhesive stored in the second region is supplied to the first region from the communication port, and in the first region, the first sheet Adhesive supplied from the communication port is deposited on the outer peripheral surface of the roller located on the opposite side of the main surface, and the roller rotates to fill the grooves on the outer peripheral surface of the roller. The said adhesive agent is related with the manufacturing apparatus of a laminated body by which the said main surface is spread | dispersed from the said 1st clearance gap.

  According to the present invention, peeling between sheets of a laminate is suppressed.

It is sectional drawing which shows typically the spraying apparatus which concerns on one Embodiment of this invention. It is sectional drawing which expands and shows the state which has arrange | positioned the braid | blade and the braid | blade holding | maintenance to the principal part of the spraying apparatus of FIG. It is a perspective view which shows the roller used in FIG. It is a top view which shows the braid | blade and blade press which concern on one Embodiment of this invention. It is a top view which shows the braid | blade and blade press which concerns on other one Embodiment of this invention. It is a figure which shows the manufacturing apparatus of the laminated body which concerns on one Embodiment of this invention.

  The manufacturing method of the laminated body which concerns on this invention is a preparation process which prepares a 1st sheet | seat and a 2nd sheet | seat, and the spreading | diffusion apparatus arrange | positioned above the main surface on one main surface of a 1st sheet | seat. An adhesive spraying step of spraying particles; and a laminating step of laminating the second sheet on the first sheet via the adhesive.

As shown in FIG. 1, the spraying device 5 includes a storage unit 6 that stores the particulate adhesive 4 and a roller 7. The roller 7 rotates as the rotating shaft 10 rotates. The reservoir 6 is provided with a slit-shaped opening 6 </ b> A along the axial direction of the roller 7 so as to face the first sheet 1. The roller 7 is fitted into the opening 6A of the reservoir 6 so that a first gap G1 (G1 _L , G1 _R ) is formed along the longitudinal direction of the opening 6A (that is, the axial direction of the roller 7). . The width of the first gap G1 is not particularly limited, and may be set as appropriate in consideration of the particle diameter of the adhesive 4 and the spraying amount. The width of the first gap G1 may be, for example, 0.1 to 0.5 mm.

The outer peripheral surface of the roller 7 is knurled, and for example, a lattice-shaped groove D as shown in FIG. The particulate adhesive 4 stored in the storage unit 6 is embedded in the groove D on the storage unit 6 side by its own weight. When the roller 7 rotates counterclockwise, from the first gap (the first gap G1 _L on the left side in FIG. 1) that first appears on the main surface side of the first sheet 1 the groove D on the storage section 6 side, The adhesive 4 in 6 is directly sprayed on the first sheet 1, and part of the adhesive 4 embedded in the groove D is detached and sprayed on the first sheet 1. On the other hand, in the first gap (the first gap G1 _R on the right side in FIG. 1) in which the groove D on the main surface side of the first sheet 1 wraps around to the storage portion 6 side, the adhesive remaining in the groove D The agent 4 is removed by being scraped off at the opening end of the storage unit 6 and sprayed on the first sheet 1. In addition, the pattern of the groove | channel D is not specifically limited, A lattice may be sufficient and a dot, a stripe, etc. may be sufficient.

Thus, when the roller 7 rotates, the adhesive 4 in the reservoir 6 and the adhesive 4 in the groove D are arranged along the axial direction of the roller 7 (G1 _L and G1 _R ). To the first sheet 1 evenly. Furthermore, by moving or swinging at least one of the spraying device 5 and the first sheet 1, the adhesive 4 is sprayed uniformly over the entire one main surface of the first sheet 1. Therefore, the first sheet 1 and the second sheet (not shown) are bonded with a uniform bonding strength as a whole. As a result, in the obtained laminate (not shown), peeling between sheets is suppressed. Further, when the first sheet 1 and the second sheet have air permeability, the adhesive 4 is in the form of particles. Therefore, even if the adhesive 4 is sprayed over the entire main surface of the first sheet 1, An increase in pressure loss is suppressed.

  A control plate 8 is disposed in the reservoir 6 so as to cross the inside. The control plate 8 partitions the interior of the storage section 6 into a first region R1 on the opening 6A side and a second region R2 other than the first region R1. The first region R1 and the second region R2 communicate with each other by, for example, a slit-shaped communication port 9 along the axial direction of the roller 7. The adhesive 4 stored in the second region R2 is supplied from the communication port 9 to the first region R1. In the first region R1, the adhesive 4 supplied from the communication port 9 is deposited on the outer peripheral surface of the roller 7.

Adhesive 4 that is sprayed directly (without passing through the groove D) from the first gap G1 _L is a circumferential surface of the roller 7, under gravity of the adhesive agent 4 is deposited in the vicinity of the first gap G1 _L Fall. Therefore, with the progress of spraying process, the amount of the adhesive 4 in the first region R1 is gradually reduced, the amount of the adhesive 4 is also in progressively less tends to be sprayed directly from the first gap G1 _L. That is, the amount of adhesive 4 applied may be uneven at the beginning and end of the application step. By disposing the control plate 8 in the storage unit 6, it becomes easy to control the amount of the adhesive 4 deposited in the vicinity of the first gap G <b> 1 during the spraying process, and thus the dispersion of the spraying amount of the adhesive 4 is suppressed. The

The communication port 9 may be disposed above the first gap G1 _L (that is, the first gap where the groove D on the storage portion 6 side of the roller 7 first appears on the main surface side of the first sheet 1). The first gap G1 _R (that is, the first gap in the direction in which the groove D on the main surface side of the first sheet 1 wraps around the storage section 6) may be disposed above. In the former case, a relatively large amount of adhesive 4 is sprayed from the beginning to the end of the spraying process, and in the latter case, a relatively small amount of adhesive 4 is sprayed. Especially, when the 1st sheet | seat 1 and the 2nd sheet | seat have air permeability, the latter case is preferable at the point which the increase of the pressure loss of the laminated body obtained is easy to be suppressed.

  The angle θ formed between the main surface of the control plate 8 on the first region R1 side and the horizontal plane is preferably 50 to 80 degrees, and more preferably 60 to 70 degrees. When the angle θ is within this range, a space is easily formed between the control plate 8 and the adhesive 4 deposited on the outer peripheral surface of the roller 7 in the first region R1, and the spray amount of the adhesive 4 is controlled. It is easy to be done. If the angle θ is too small, the adhesive 4 is difficult to be supplied from the communication port 9 to the first region R1, and if the angle θ is too large, the amount of the adhesive 4 deposited on the outer peripheral surface of the roller 7 can be controlled. It becomes difficult.

  As shown in FIG. 2, the spraying device 5 preferably includes a blade 11. Thereby, it becomes easy to control the spraying amount of the adhesive 4. The blade 11 is, for example, a long plate-like body along the axial direction of the roller 7, and a second gap G2 narrower than the first gap G1 is formed between the blade 11 and the outer peripheral surface of the roller 7, and The tip portion is disposed so as to protrude toward the main surface of the first sheet 1 with respect to the opening 6A. The blade 11 is, for example, a flat plate having a predetermined length (for example, 500 to 1000 mm), a width of 10 to 30 mm, and a thickness of 0.1 to 2 mm. The material of the blade 11 is not particularly limited, but is preferably a metal from the viewpoint of strength. The kind of metal used for the blade 11 is not particularly limited, and examples thereof include stainless steel and aluminum. The second gap G <b> 2 is not particularly limited as long as it is smaller than the first gap G <b> 1, and may be appropriately set in consideration of the amount of adhesive 4 applied. The second gap G2 may be, for example, 0.01 to 0.05 mm.

When the blade 11 is disposed, the adhesive 4 in the storage unit 6 is sprayed on the first sheet 1 through the first gap G1 _L and the second gap G2 _L. The adhesive 4 embedded in the groove D is scraped by the ends of the second gap G2 _R side of the blade 11, it is sprayed into the first sheet 1. Therefore, the spreading amount of the adhesive 4 can be easily controlled by moving the blade 11 and changing the size of the second gap G2.

  When the spraying device 5 includes the blade 11, it is preferable to dispose the blade presser 12 outside the blade 11. The blade presser 12 is disposed such that the tip portion does not protrude toward the main surface side of the first sheet 1 relative to the blade 11. For example, as shown in FIG. 4A, the blade 11 and the blade presser 12 are fixed by a plurality of bolts 13. Since the position of the blade 11 is fixed by the blade presser 12, the second gap G2 can be easily controlled to a predetermined size. The blade presser 12 is particularly useful when the thickness of the blade 11 is small (for example, 0.5 to 3 mm). This is because when the thickness of the blade 11 is small, the blade 11 that is a long plate-like body is large and easily corrugated, and the size of the second gap G <b> 2 may vary along the axial direction of the roller 7. Further, the size of the second gap G <b> 2 may vary along the axial direction of the roller 7 depending on the processing accuracy of the groove D of the roller 7.

  The blade presser 12 is, for example, a flat plate having a predetermined length (for example, 500 to 1000 mm), a width of 15 to 40 mm, and a thickness of 2 to 5 mm. The material of the blade presser 12 is not particularly limited, but is preferably a metal from the viewpoint of strength. The kind of metal used for the blade presser 12 is not particularly limited, and examples thereof include stainless steel and aluminum.

  In particular, as shown in FIG. 4B, it is preferable that the plurality of blade pressers 12A be arranged along the axial direction of the roller 7 (that is, the longitudinal direction of the blade 11). When the blade presser 12 is long, the undulation of the blade presser 12 tends to increase. Therefore, when the blade 11 is fixed with one long blade presser 12, the width of the second gap G2 may vary along the axial direction of the roller 7. By dividing the blade retainer 12 and shortening the length of the blade 11 of the blade retainer 12A in the longitudinal direction, the undulation of the blade retainer 12A can be suppressed. In this case, the plurality of blade pressers 12 </ b> A are each fixed to the blade 11 by one or more bolts 13. Therefore, the distance between the plurality of blade holders 12A and the blades 11 can be adjusted by the respective bolts 13 that fix the blade holders 12A. Therefore, it is easy to make the size of the second gap G2 constant along the axial direction of the roller 7 in consideration of the degree of undulation of the blade 11 and the like. The number of blade pressers 12A is not particularly limited, and may be set as appropriate in consideration of the length of the blade 11 and the degree of undulation. The number of blade pressers 12A may be, for example, 2 to 20.

  Hereinafter, although the manufacturing method of this invention is demonstrated centering on the case where a laminated body is a filter medium, the use of a laminated body is not limited to this.

(1) Preparation Step In the preparation step, the first sheet 1 and the second sheet are prepared. The first sheet 1 is, for example, a support (base material) that supports the laminated body, and the second sheet exhibits a dust collecting function, and when third fibers to be described later are deposited on the first sheet 1. Functions as a protective layer that protects the third fibers from external loads.

  The form and material of the 1st sheet | seat 1 are not specifically limited, What is necessary is just to select suitably according to a use. Specific examples of the first sheet 1 include fiber structures such as resin sheets, paper sheets, woven fabrics, knitted fabrics, and nonwoven fabrics. Especially, when using a laminated body as a filter medium, it is preferable that the 1st sheet | seat 1 is a nonwoven fabric from a viewpoint of pressure loss. The nonwoven fabric is manufactured by, for example, a spunbond method, a dry method (for example, airlaid method), a wet method, a melt blow method, a needle punch method, or the like. Especially, it is preferable that the 1st sheet | seat 1 is a nonwoven fabric manufactured by the wet method at the point in which the nonwoven fabric suitable as a base material is easy to be formed.

  When the 1st sheet | seat 1 is a nonwoven fabric, the material of the 1st fiber which comprises the 1st sheet | seat 1 is not specifically limited, For example, glass fiber, a cellulose, an acrylic resin, a polypropylene (PP), polyethylene (PE), polyester ( Examples thereof include polyethylene terephthalate (PET), polybutylene terephthalate), polyamide (PA), or a mixture thereof. Especially, the point which is suitable as a base material WHEREIN: The material of a 1st fiber has a preferable PET or a cellulose. The average fiber diameter D1 of the first fibers is not particularly limited, and may be, for example, 1 μm or more and 40 μm or less, or 5 μm or more and 20 μm or less.

  The average fiber diameter D1 is an average value of the diameters of the first fibers. The diameter of the first fiber is a diameter of a cross section perpendicular to the length direction of the first fiber. If such a cross section is not circular, the maximum diameter may be considered as the diameter. Moreover, you may regard the width | variety of the direction perpendicular | vertical to the length direction of a 1st fiber when the 1st sheet | seat 1 is seen from the normal line direction of one main surface as a diameter of a 1st fiber. The average fiber diameter D1 is, for example, an average value of the diameters of arbitrary portions of arbitrary ten first fibers included in the first sheet 1. The same applies to average fiber diameters D2 and D3 described later.

  The thickness T1 of the 1st sheet | seat 1 is not specifically limited, For example, 50 micrometers or more and 500 micrometers or less may be sufficient, and 150 micrometers or more and 400 micrometers or less may be sufficient. The sheet thickness T is, for example, an average value of the thicknesses at arbitrary 10 positions of the sheet (hereinafter the same). The thickness is a distance between the two main surfaces of the sheet. When the sheet is a non-woven fabric, the thickness is taken by taking a cross-section of the non-woven fabric and drawing a line perpendicular to one surface from any one point on one main surface of the non-woven fabric to the other main surface. It is calculated | required as the distance of the outer side (outside method) of two fibers in the most distant position among the fibers on this line. The thickness of the nonwoven fabric is calculated in the same manner for other arbitrary plural points (for example, 9 points), and a value obtained by averaging these is set as the thickness of the nonwoven fabric. In calculating the thickness, a binarized image may be used.

The mass per unit area of the first sheet 1 is not particularly limited, and may be, for example, 10 g / m ² or more and 80 g / m ² or less, or 35 g / m ² or more and 60 g / m ² or less. good.

  The pressure loss of the first sheet 1 is not particularly limited. Especially, when the initial pressure loss of the 1st sheet | seat 1 is measured using the measuring machine based on the standard of JISB9908 format 1, it is preferable that it is about 1 Pa or more and 10 Pa or less. If the initial pressure loss of the 1st sheet | seat 1 is this range, the pressure loss of the whole laminated body will also be suppressed.

  The second sheet may be, for example, a nonwoven fabric manufactured by the above method. Especially, when using a laminated body as a filter medium, it is preferable that the 2nd sheet | seat is a nonwoven fabric manufactured by the melt blow method at the point which a nonwoven fabric with a thin fiber diameter is easy to be formed. Furthermore, it is preferable that the second nonwoven fabric is charged (permanently charged) by charging treatment or the like in that a dust collection effect can be expected. Permanent charging is a state in which electric polarization is maintained semipermanently in the absence of an external electric field and an electric field is formed with respect to the surroundings.

  The material of the 2nd fiber which comprises a 2nd sheet | seat is not specifically limited, For example, polyester, PA, such as glass fiber, a cellulose, an acrylic resin, PP, PE, and PET, or these mixtures etc. are mentioned. Among these, PP is preferable because it is easily charged. The average fiber diameter D2 of the second fibers is not particularly limited. The average fiber diameter D2 may be, for example, 0.5 μm or more and 20 μm or less, or 5 μm or more and 20 μm or less.

The thickness T2 of the second sheet is not particularly limited, and may be 100 μm or more and 500 μm or less, or 150 μm or more and 400 μm or less. The mass per unit area of the second sheet is not particularly limited, and may be 10 g / m ² or more and 50 g / m ² or less, or 10 g / m ² or more and 30 g / m ² or less.

  The pressure loss of the second sheet is not particularly limited. Especially, it is preferable that the initial pressure loss of a 2nd sheet | seat is about 10 Pa or more and 50 Pa or less when measuring on the conditions similar to the above. If the initial pressure loss of the second sheet is within this range, the pressure loss of the entire laminate is also suppressed.

(2) Electrospinning process Before the adhesive dispersion | spreading process mentioned later, you may deposit a fiber (3rd fiber) by the electrospinning method on the main surface where the adhesive agent of the 1st sheet | seat 1 is spread | dispersed (electrospinning). Process). When the laminate is used as a filter medium, an improvement in dust collection performance can be expected. In this step, the first sheet 1 is a target of the raw material liquid to be injected, and functions as a collector that collects the third fibers to be generated. The second sheet also functions as a protective material that protects the third fibers deposited on the first sheet 1. In this case, the first sheet 1 and the second sheet are laminated via the third fiber. When performing an electrospinning process, the raw material liquid containing the raw material resin used as the raw material of a fiber and the solvent which dissolves raw material resin is prepared.

  The raw material liquid contains a raw material resin and a solvent. The raw material resin is a raw material of the third fiber, and the solvent dissolves the raw material resin (hereinafter referred to as the first solvent). A fiber containing a raw material resin and a first solvent is formed from the raw material liquid. The mixing ratio of the raw material resin and the first solvent in the raw material liquid varies depending on the type of the selected raw material resin and the type of the first solvent. The ratio of the 1st solvent in a raw material liquid is 60 mass% to 95 mass%, for example. The raw material liquid may contain a solvent other than the first solvent for dissolving the raw material resin, various additives, and the like.

  The type of raw material resin is not particularly limited. For example, polyamide (PA), polyimide (PI), polyamideimide (PAI), polyetherimide (PEI), polyacetal (POM), polycarbonate (PC), polyetheretherketone ( PEEK), polysulfone (PSF), polyethersulfone (PES), polyphenylene sulfide (PPS), polytetrafluoroethylene (PTFE), polyarylate (PAR), polyacrylonitrile (PAN), polyvinylidene fluoride (PVDF), polyvinyl Examples of the polymer include alcohol (PVA), polyvinyl acetate (PVAc), polypropylene (PP), polyethylene terephthalate (PET), and polyurethane (PU). You may use these individually or in combination of 2 or more types. Among these, PES is preferable because it is suitable for the electrospinning method. Moreover, PVDF is preferable at the point which the average fiber diameter D3 tends to become thin.

  The first solvent is not particularly limited as long as it can dissolve the raw material resin. For example, methanol, ethanol, 1-propanol, 2-propanol, hexafluoroisopropanol, tetraethylene glycol, triethylene glycol, dibenzyl alcohol, 1,3-dioxolane, 1,4-dioxane, methyl ethyl ketone, methyl isobutyl ketone, methyl- n-hexyl ketone, methyl-n-propyl ketone, diisopropyl ketone, diisobutyl ketone, acetone, hexafluoroacetone, phenol, formic acid, methyl formate, ethyl formate, propyl formate, methyl benzoate, ethyl benzoate, propyl benzoate, acetic acid Methyl, ethyl acetate, propyl acetate, dimethyl phthalate, diethyl phthalate, dipropyl phthalate, methyl chloride, ethyl chloride, methylene chloride, chloroform, o-chlorotoluene, p- Lorotoluene, carbon tetrachloride, 1,1-dichloroethane, 1,2-dichloroethane, trichloroethane, dichloropropane, dibromoethane, dibromopropane, methyl bromide, ethyl bromide, propyl bromide, acetic acid, benzene, toluene, hexane, cyclohexane , Cyclohexanone, cyclopentane, o-xylene, p-xylene, m-xylene, acetonitrile, tetrahydrofuran, N, N-dimethylformamide, N, N-dimethylacetamide (DMAc), dimethyl sulfoxide, pyridine, water, etc. Can do. These may be used alone or in combination of two or more. Among these, DMAc is preferable because it is suitable for the electrospinning method and easily dissolves PES.

  The average fiber diameter D3 of the third fibers to be deposited is not particularly limited, and may be set as appropriate according to the application. Especially, when using a laminated body as a filter medium, it is preferable that average fiber diameter D3 is smaller than average fiber diameter D1 and D2. Specifically, the average fiber diameter D3 is preferably 3 μm or less, more preferably 1 μm or less, and particularly preferably 500 nm or less. Further, the average fiber diameter D3 is preferably 50 nm or more, and more preferably 100 nm or more. This is because when the laminate is used as a filter medium, pressure loss is suppressed and dust collection efficiency is likely to be high. The third fiber may include a plurality of types of fibers having different average fiber diameters.

The amount of deposition of the third fiber is not particularly limited. Among them, when using the laminate as a filter medium, the deposition amount of the third fiber, from the viewpoint of the balance between pressure loss and dust collection efficiency, 0.1 g / ^{m 2} or more, is 1.5 g / ^{m 2} or less It is preferably 0.2 g / m ² or more and 0.5 g / m ² or less, more preferably 0.2 g / m ² or more and 0.8 g / m ² or less.

(3) Adhesive spraying process The adhesive 4 is sprayed on the first sheet 1 in the form of particles by a spraying device 5 as shown in FIG. Thereby, the adhesive 4 is uniformly spread on the first sheet 1. The average particle diameter D50 of the particulate adhesive 4 is not particularly limited, and is, for example, 150 to 350 μm and 180 to 300 μm. The average particle diameter D50 is a median diameter in a volume particle size distribution obtained by a laser diffraction particle size distribution measuring apparatus (hereinafter the same).

  The kind of the adhesive agent 4 is not specifically limited, For example, the adhesive agent etc. which have a thermoplastic resin as a main component are mentioned. Examples of the thermoplastic resin include polyesters such as PU and PET, copolymer polyesters such as urethane-modified copolymer polyester, PA, and polyolefins (eg, PP and PE). The melting point of the adhesive 4 is preferably about 60 to 140 ° C.

Average weight of the adhesive 4 to adhere to the layered nonwoven fabric is not particularly limited, from the viewpoint of adhesion and pressure loss, 0.5 g / ^{m 2} or more, preferably 15 g / ^{m 2} or less, 1 g / ^{m 2} As mentioned above, it is more preferably 10 g / m ² or less, and particularly preferably 3 g / m ² or more and 9 g / m ² or less.

(4) Lamination process Finally, a 2nd sheet | seat is laminated | stacked on the 1st sheet | seat 1 through the adhesive agent 4, and a laminated body is obtained.

  In the method for producing a laminated nonwoven fabric as described above, for example, the first sheet 1 is conveyed from the upstream to the downstream of the line, the third fibers are deposited on the main surface of the conveyed first sheet 1, and then the second sheet It is possible to implement by the manufacturing system which laminates | stacks. Such a production system includes, for example, (1) a first sheet supply unit that supplies the first sheet 1 to the transport belt, and (2) an electric field having an electrospinning mechanism that generates third fibers from the raw material liquid by electrostatic force. A spinning section; (3) an adhesive spraying section for spraying the adhesive 4 from above the first sheet fed from the electrospinning section; (4) a heating section for melting the sprayed adhesive 4; ) A second sheet stacking unit that stacks the second sheet from above the first sheet 1 fed from the heating unit.

  Hereinafter, the manufacturing system will be described with reference to FIG. 5, but the following system and manufacturing method do not limit the present invention. FIG. 5 is a diagram schematically showing an example of the configuration of the manufacturing system 200 for the laminate 17. The manufacturing system 200 constitutes a manufacturing line for manufacturing the laminate 17.

  First, the first sheet 1 is prepared. In the manufacturing system 200, the first sheet 1 is conveyed from upstream to downstream of the manufacturing line. The most upstream of the manufacturing system 200 is provided with a first sheet supply unit 201 that houses therein the first sheet 1 wound in a roller shape. The supply unit 201 rotates the first supply reel 15 by the motor 16 and supplies the first sheet 1 wound around the first supply reel 15 to the conveyance roller 14.

  The first sheet 1 is conveyed by the conveying roller 14 to an electrospinning unit 202 having an electrospinning unit (not shown). The electrospinning mechanism of the electrospinning unit includes an emitter 23 for discharging the raw material liquid 22 of the third fiber 3 installed above the electrospinning unit, and charging for positively charging the discharged raw material liquid 22. Means (described later) and a transport conveyor 21 for transporting the first sheet 1 disposed so as to face the discharge body 23 from the upstream side to the downstream side. The conveyor 21 functions as a collector unit that collects the third fibers 3 together with the first sheet 1. The number of electrospinning units is not particularly limited, and may be one or two or more.

  When there are a plurality of electrospinning units and / or emitters, the average fiber diameter of the third fibers 3 to be formed may be changed for each electrospinning unit or for each emitter. The average fiber diameter of the third fibers 3 is adjusted by adjusting the discharge pressure of the raw material liquid 22 to be described later, the applied voltage, the concentration of the raw material liquid 22, the distance between the emitter 23 and the first sheet 1, the temperature, the humidity, and the like. Can be changed. Further, the amount of deposition of the third fibers 3 is controlled by adjusting the discharge pressure of the raw material liquid 22, the applied voltage, the concentration of the raw material liquid 22, the conveyance speed of the first sheet 1, and the like.

  On the side of the emitter 23 facing the main surface of the first sheet 1, a plurality of outlets (not shown) for the raw material liquid 22 are provided. The distance between the discharge port of the discharge body 23 and the first sheet 1 may be, for example, 100 to 600 mm, although it depends on the scale of the manufacturing system and the desired fiber diameter. The emitter 23 is installed above the electrospinning unit, and the second support 25 extending downward from the first support 24 parallel to the conveying direction of the first sheet 1 causes the longitudinal direction of the emitter 23 to be the first sheet 1. It is supported so as to be parallel to the main surface. The first support 24 may be movable so as to swing the emitter 23 in a direction perpendicular to the conveyance direction of the first sheet 1.

  The charging means includes a voltage applying device 26 that applies a voltage to the emitter 23 and a counter electrode 27 that is installed in parallel with the transport conveyor 21. The counter electrode 27 is grounded. Thereby, a potential difference (for example, 20 to 200 kV) according to the voltage applied by the voltage application device 26 can be provided between the emitter 23 and the counter electrode 27. The configuration of the charging unit is not particularly limited. For example, the counter electrode 27 may be negatively charged. Moreover, you may comprise the belt part of the conveyance conveyor 21 from a conductor instead of providing the counter electrode 27. FIG.

  The emitter 23 is made of a conductor, has a long shape, and is hollow inside. The hollow portion serves as a storage portion that stores the raw material liquid 22. The raw material liquid 22 is supplied from the raw material liquid tank 29 to the hollow of the emitter 23 by the pressure of the pump 28 communicating with the hollow portion of the emitter 23. Then, the raw material liquid 22 is discharged from the discharge port toward the main surface of the first sheet 1 by the pressure of the pump 28. The discharged raw material liquid 22 is electrostatically exploded while moving in the space (generation space) between the emitter 23 and the first sheet 1 in a charged state, and the fibrous material (third fiber 3) is caused to move. Generate. The generated third fibers 3 are deposited on the first sheet 1.

  The electrospinning mechanism that forms the third fiber 3 is not limited to the above configuration. Any mechanism that can generate the third fiber 3 from the raw material liquid 22 by electrostatic force in a predetermined generation space of the third fiber 3 and deposit the generated third fiber 3 on the main surface of the first sheet 1. It can be used without any particular limitation. For example, the shape of the cross section perpendicular to the longitudinal direction of the emitter 23 may be a shape (V-type nozzle) that gradually decreases from the top to the bottom.

  After the 3rd fiber 3 is deposited, the 1st sheet | seat 1 is conveyed to the adhesive agent distribution part 203. FIG. The first sheet 1 is conveyed by the conveyance roller 31. The adhesive spraying unit 203 includes a spraying device 5 as shown in FIG. In the adhesive spraying unit 203, the adhesive 4 is sprayed uniformly by the spraying device 5 from the side where the third fibers 3 of the first sheet 1 are deposited.

  After the adhesive 4 is sprayed and before the second sheet 2 is laminated, the adhesive 4 is melted by the heating unit 204 including the heating device 42. In the heating unit 204, the solvent contained in the third fiber 3 is also removed.

  The heating device 42 is not particularly limited, and a known device may be appropriately selected. The heating temperature may be appropriately set according to the boiling point of the solvent and the melting point of the adhesive 4. The heating temperature is adjusted so that the surface of the first sheet 1 is preferably 100 to 200 ° C, more preferably 120 to 170 ° C.

  Next, the first sheet 1 on which the adhesive 4 has been spread is conveyed to the second sheet stacking unit 205 by the conveyance roller 41. In the second sheet stacking unit 205, the second sheet 2 is supplied from above the first sheet 1 and is stacked on the first sheet 1 via the adhesive 4 and the third fibers 3. When the second sheet 2 is long, the second sheet 2 may be wound around the second supply reel 52 in the same manner as the first sheet 1. In this case, the second sheet 2 is stacked on the first sheet 1 while being rolled out from the second supply reel 52. The first sheet 1 is conveyed by the conveyance roller 51.

  After the second sheet 2 is laminated, the laminated body 17 is pressed while applying pressure by a pair of pressure rollers 53 (53a and 53b) arranged above and below the laminated body 17, so that the first sheet 1 and the first sheet 1 You may make 2 sheet | seat 2 contact | adhere further.

  Finally, the laminated body 17 is carried out from the second sheet laminating unit 205 and conveyed via the roller 61 to the collecting unit 206 arranged on the further downstream side. The collection unit 206 includes, for example, a collection reel 62 that scrapes off the stacked body 17 being conveyed. The collection reel 62 is rotationally driven by a motor 63.

  In the laminate of the present invention, separation between sheets is suppressed, so an air cleaner or an air conditioner filter medium, a separation sheet for a battery, a membrane for a fuel cell, an in vitro test sheet such as a pregnancy test sheet, a cell culture It is suitable as a medical sheet for medical use, a dustproof cloth such as a dustproof mask, a dustproof clothing, a cosmetic sheet, a wiping sheet for wiping off dust, and the like.

1: 1st sheet, 2: 2nd sheet, 3: 3rd fiber, 4: adhesive, 5: spraying device, 6: reservoir, 6A: opening, 7: roller, 8: control plate, 9: communication port 10: Rotating shaft, 11: Blade, 12, 12A: Blade presser, 13: Bolt, 14, 31, 41, 51: Conveying roller, 15: First supply reel, 16: Motor, 17: Laminate, 21: Transport conveyor, 22: raw material liquid, 23: discharger, 24: first support, 25: second support, 26: voltage application device, 27: counter electrode, 28: pump, 29: raw material tank, 42: Heating device, 52: second supply reel, 53, 53a, 53b: pressure roller, 61: roller, 62: collection reel, 63: motor, 200: manufacturing system, 201: first sheet supply unit, 202: electrospinning Part, 203: adhesive spraying part, 204: Thermal unit, 205: second sheet stacking portion, 206: recovery unit

Claims (4)

A preparation step of preparing the first sheet and the second sheet;
By electrospinning, the fiber containing the raw material resin is produced from a raw material liquid containing a raw material resin that is a raw material of the fiber and a solvent that dissolves the raw material resin, and the fiber is one main surface of the first sheet. An electrospinning process to be deposited on
On the main surface of said first sheet, wherein the fibers are deposited, the arranged sparging device above the major surface, an adhesive spraying step of spraying particles of adhesive,
A lamination step of laminating the second sheet on the first sheet via the adhesive,
The spraying device includes the reservoir that stores the adhesive and includes an opening facing the main surface, and a roller that is fitted into the opening so that a first gap is formed,
The roller has a groove on the outer peripheral surface;
The reservoir comprises a control plate arranged to traverse the interior;
The control plate divides the interior of the reservoir into a first region on the opening side and a second region other than the first region;
The first region and the second region communicate with each other through a communication port,
From the communication port, the adhesive stored in the second region is supplied to the first region,
In the first region, the adhesive supplied from the communication port is deposited on the outer peripheral surface of the roller located on the opposite side of the main surface of the first sheet,
The manufacturing method of a laminated body, wherein the adhesive spraying step rotates the roller and sprays the adhesive buried in the groove on the outer peripheral surface of the roller from the first gap to the main surface.   The manufacturing method of the laminated body of Claim 1 whose angle which the main surface of the said control plate and a horizontal surface make is 50-80 degree | times.   The manufacturing method of the laminated body of Claim 1 or 2 with which the space is formed in the said 1st area | region between the said control plate and the said adhesive agent deposited on the said outer peripheral surface. An electrospinning unit for generating the fiber containing the raw material resin from a raw material liquid containing a raw material resin as a raw material of the fiber and a solvent for dissolving the raw material resin, and depositing the fiber on one main surface of the first sheet When,
Wherein is disposed downstream of the electrospinning unit, to the main surface of the first sheet, an adhesive spray unit for spraying particles of an adhesive,
Disposed downstream of the adhesive sprinkling part, and the first sheet is provided with a lamination part for laminating a second sheet via the adhesive,
The adhesive spraying portion includes the storage portion that stores the adhesive and includes an opening facing the main surface, and a roller that is fitted into the opening so as to form a first gap. Equipped with equipment,
The roller has a groove on the outer peripheral surface;
The reservoir comprises a control plate arranged to traverse the interior;
The control plate divides the interior of the reservoir into a first region on the opening side and a second region other than the first region;
The first region and the second region communicate with each other through a communication port,
From the communication port, the adhesive stored in the second region is supplied to the first region,
In the first region, the adhesive supplied from the communication port is deposited on the outer peripheral surface of the roller located on the opposite side of the main surface of the first sheet,
The laminated body manufacturing apparatus in which the adhesive filled in the groove on the outer peripheral surface of the roller is sprayed from the first gap to the main surface as the roller rotates.

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