JP7796085B2 - Breathable product manufacturing method and manufacturing device - Google Patents

Description

The present invention relates to technology for manufacturing breathable products such as filters, and in particular to a manufacturing method and manufacturing apparatus for manufacturing breathable products that have an adhesive layer on part of one side of a breathable substrate.

Conventionally, breathable products such as filters have been manufactured using breathable materials such as woven fabrics to prevent dust and other particles from entering a room through an air vent. Furthermore, such filters sometimes have an adhesive layer formed on one side of a breathable substrate made of nonwoven fabric or the like to facilitate attachment to the air vent.

Japanese Patent No. 6178291 describes a method for manufacturing a filter in which a hot-melt adhesive layer is provided on one side of a nonwoven fabric substrate. The manufacturing method described in Japanese Patent No. 6178291 involves preparing a rotationally driven relief roll having a predetermined raised pattern and a pressure roller that rotates in contact with the relief roll. After applying the hot-melt adhesive to the raised pattern, the nonwoven fabric is passed between the relief roll and the pressure roller, transferring the hot-melt adhesive applied to the raised pattern on the relief roll onto the nonwoven fabric. Release paper is then superimposed to cover the hot-melt adhesive, thereby manufacturing a filter having a hot-melt adhesive layer and release paper on one side of the substrate.

With this manufacturing method, when the hot melt adhesive is transferred to the nonwoven fabric, it is believed that some of the hot melt adhesive penetrates into the gaps between the fibers that make up the nonwoven fabric, thereby integrating the nonwoven fabric and the adhesive layer.

Japanese Patent No. 6178291

The manufacturing method described in Patent Document 1 has the problem that when the hot melt adhesive is transferred to a nonwoven fabric substrate, the amount of hot melt adhesive that penetrates into the gaps in the nonwoven fabric is not consistent, resulting in an inappropriate layer thickness in the portion of the adhesive layer exposed to the substrate that is uneven in some places. In the case of a filter that is attached to an attachment target such as an air vent with an adhesive layer, if the layer thickness of the exposed portion of the adhesive layer is inappropriate, gaps are likely to form between the filter and the target, which could impair collection performance or make the filter more likely to come off the target.

The present invention therefore aims to provide a manufacturing method and manufacturing apparatus that can produce breathable products with a pressure-sensitive adhesive layer whose thickness is appropriate in the portion exposed to the surface of the breathable substrate.

In order to achieve the above object, a first aspect of the present invention provides a method for producing a breathable product, the method comprising: a substrate preparation step of preparing a breathable substrate having gaps on at least one side; a hardness adjustment step of preparing a pressure-sensitive adhesive layer to be formed on part of the one side and adjusting the hardness of the pressure-sensitive adhesive layer so that only part of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate; and a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness against the breathable substrate, after the hardness adjustment step, wherein the hardness adjustment step includes a hardness increase step of increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to the side pressed against the breathable substrate, and the pressure-sensitive adhesive layer having the adjusted hardness forms an increased hardness region on the side opposite to the side pressed against the breathable substrate, and the region on the side pressed against the breathable substrate is maintained in a softened state ; the pressure-sensitive adhesive layer is made of a hot-melt pressure-sensitive adhesive, and the hot-melt pressure-sensitive adhesive is applied in an amount of 20 to 50 g/m2 ^and over an area of 40 to 80% of the entire breathable substrate .

With this configuration, when the pressure-sensitive adhesive layer with adjusted hardness is pressed against the breathable substrate, only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate, and the two are integrated. Also, a difference in hardness occurs in the thickness direction of the pressure-sensitive adhesive layer. Furthermore, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the gaps in the breathable substrate, while the increased hardness region does not penetrate into the gaps inside the breathable substrate.
A method for producing a breathable product in a second aspect of the present invention is a method for producing a breathable product in which an adhesive layer is formed on one side of a breathable substrate having gaps on at least one side, a release sheet is placed on the surface side of the adhesive layer, the release sheet is peeled off, and the breathable substrate portion is attached to an object to be attached using the adhesive layer, the method comprising the steps of: preparing an adhesive layer to be formed on a portion of the one side; and forming the adhesive layer on the release sheet; and adjusting the hardness of the adhesive layer formed on the release sheet so that only a portion of the adhesive layer penetrates into the gaps in the breathable substrate. The method comprises an adjusting step, a substrate preparing step of preparing a breathable substrate, and a pressing step of pressing an adhesive layer having the adjusted hardness onto the breathable substrate after the hardness adjusting step, wherein the hardness adjusting step includes a hardness increasing step of increasing the hardness of a region including the surface of the adhesive layer opposite to the surface pressed onto the breathable substrate, and the hardness increasing step includes a cooling step of cooling the surface of the release sheet opposite to the surface on which the adhesive layer is formed, and the pressing step includes a step of pressing the adhesive layer having the adjusted hardness of the release sheet onto the breathable substrate to integrate the release sheet and the breathable substrate.
In this configuration, by pressing the pressure-sensitive adhesive layer with adjusted hardness against the breathable substrate, only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate, and the two are integrated. Also, a difference in hardness in the thickness direction of the pressure-sensitive adhesive layer occurs. Furthermore, the release sheet and the breathable substrate are integrated in a state where the hardness of the pressure-sensitive adhesive layer is adjusted to a constant layer thickness on the release sheet in advance, and the surface of the pressure-sensitive adhesive layer is molded by the release sheet, so that it becomes flush and smooth.
A method for producing a breathable product according to a third aspect of the present invention is such that, in the configuration of the invention according to the second aspect, the pressure-sensitive adhesive layer having an adjusted hardness has an increased hardness region formed on the surface opposite to the surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region.
With this configuration, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the voids in the breathable substrate, whereas the increased hardness region does not penetrate into the gaps inside the breathable substrate.
A method for producing a breathable product according to a fourth aspect of the present invention is the same as the method according to the first or third aspect of the present invention, in which the pressure-sensitive adhesive layer having an adjusted hardness changes continuously in the layer direction from the increased hardness region to the softened state region.
With this configuration, the layer thickness of the increased hardness region is made uniform.

A fifth aspect of the present invention provides a method for producing a breathable product, wherein, in the configuration of the invention of the first aspect, the pressure-sensitive adhesive layer is made of a hot-melt pressure-sensitive adhesive, and the hardness-increasing step includes a cooling step of cooling a region of the softened pressure-sensitive adhesive layer that includes a surface opposite to the surface pressed against the breathable substrate .

When configured in this manner, the adhesive is a hot melt adhesive, which increases the hardness of the cooled areas of the adhesive layer.

A method for producing a breathable product according to a sixth aspect of the present invention is the same as that according to the fifth aspect of the invention, in which the cooling step comprises the steps of preparing a release sheet having a pressure-sensitive adhesive layer made of a softened hot-melt pressure-sensitive adhesive formed on one side thereof, and cooling the surface of the release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed.

By configuring it in this way, the side of the release sheet opposite the side on which the adhesive layer is formed is cooled, increasing the hardness of the area of the adhesive layer close to the release sheet. Because the surface of the adhesive layer is shaped by the release sheet, it becomes flush and smooth.

A seventh aspect of the present invention provides a method for producing a breathable product, wherein in the configuration of the invention of the second or sixth aspect, the step of cooling the release sheet includes a step of engaging the release sheet with a metal roll having a temperature lower than that of the pressure-sensitive adhesive layer of the release sheet.

By configuring it in this way, engaging a low-temperature metal roll with the release sheet reduces the temperature of the pressure-sensitive adhesive layer in the area adjacent to the release sheet, increasing its hardness.

In an eighth aspect of the present invention, there is provided a method for producing a breathable product according to any one of the first to seventh aspects of the present invention, wherein the breathable substrate is made of a nonwoven fabric.

When configured in this way, by pressing the adhesive layer against the breathable substrate, part of the adhesive layer penetrates into the gaps between the fibers of the nonwoven fabric that makes up the breathable substrate, and after curing, the breathable substrate and the adhesive layer become integrated.

A ninth aspect of the present invention provides a method for producing a breathable product according to any one of the first to eighth aspects of the invention, wherein the breathable product is a filter.

By configuring it in this way, a filter product is produced that has an adhesive layer with an appropriate layer thickness in the portion exposed to the surface of the breathable substrate.

A method for producing a breathable product in a tenth aspect of the present invention is a method for producing a breathable product in the configuration of any one of the second , third, and fifth to seventh aspects of the invention, wherein the breathable product is an electrostatic filter.

By configuring in this manner, an electrostatic filter having an adhesive layer made of a hot melt adhesive is produced.
A method for producing a breathable product in an eleventh aspect of the present invention is a method for producing a breathable product in which an adhesive layer is formed on one side of a breathable substrate having gaps on at least one side, a release sheet is arranged on the surface side of the adhesive layer, the release sheet is peeled off, and the breathable substrate portion is attached to an object to be attached using the adhesive layer, the method comprising the steps of: preparing an adhesive layer to be formed on a portion of the one side, and forming the adhesive layer on the release sheet; a hardness adjusting step of adjusting the hardness of the adhesive layer formed on the release sheet so that only a portion of the adhesive layer penetrates into the gaps in the breathable substrate; The method comprises a substrate preparation step of preparing a breathable substrate, and a pressing step of pressing an adhesive layer having the adjusted hardness onto a breathable substrate after a hardness adjustment step, wherein the hardness adjustment step includes a hardness increase step of increasing the hardness of a region including the surface of the adhesive layer opposite to the surface pressed against the breathable substrate, and the adhesive layer having the adjusted hardness has an increased hardness region formed on the surface opposite to the surface pressed against the breathable substrate, and the region of the surface pressed against the breathable substrate is maintained in a softened state, and the hardness increase step includes a cooling step of cooling the surface of the release sheet opposite to the surface on which the adhesive layer is formed.
With this configuration, when the pressure-sensitive adhesive layer with adjusted hardness is pressed against the breathable substrate, only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate, and the two are integrated. Also, a difference in hardness occurs in the thickness direction of the pressure-sensitive adhesive layer. Furthermore, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the gaps in the breathable substrate, while the increased hardness region does not penetrate into the gaps inside the breathable substrate.

In a twelfth aspect of the present invention, there is provided an apparatus for producing a breathable product, in which an adhesive layer is formed on one side of a breathable substrate having a gap on at least one side thereof, and a release sheet is arranged on the surface side of the adhesive layer, and the release sheet is peeled off and the breathable substrate portion is attached to an object to be attached using the adhesive layer, the apparatus comprising: substrate supply means for supplying the breathable substrate; release sheet supply means for supplying the release sheet; adhesive supply means for supplying the adhesive; adhesive application means for applying the adhesive supplied from the adhesive supply means to a part of one side of the release sheet supplied from the release sheet supply means to form an adhesive layer; and and a pressing means for pressing the breathable substrate supplied from the substrate supply means onto an adhesive layer having a hardness adjusted by the hardness adjusting means, wherein the hardness adjusting means includes a hardness increasing means for increasing the hardness of a region including the surface of the adhesive layer opposite to the surface pressed against the breathable substrate, and the adhesive layer having the adjusted hardness has an increased hardness region formed on the surface opposite to the surface pressed against the breathable substrate, and the region of the surface pressed against the breathable substrate is maintained in a softened state, and the hardness increasing means includes a cooling means for cooling the side of the release sheet opposite to the surface on which the adhesive layer is formed.

When configured in this manner, the hardness of the adhesive layer applied to the release sheet by the adhesive application means is adjusted by the hardness adjustment means, and then the breathable substrate is pressed against the adhesive layer by the pressing means, thereby laminating the adhesive layer and the release sheet on one side of the breathable substrate and allowing part of the adhesive layer to penetrate into the gaps in the breathable substrate, resulting in a manufacturing device that can produce a breathable product with an integrated structure.
In a thirteenth aspect of the present invention, a manufacturing apparatus for a breathable product is provided, in which an adhesive layer is formed on one surface of a breathable substrate having a gap on at least one surface side, and a release sheet is arranged on the surface side of the adhesive layer, and the release sheet is peeled off and the breathable substrate portion is attached to an object to be attached using the adhesive layer, the manufacturing apparatus for a breathable product comprising: substrate supply means for supplying the breathable substrate; release sheet supply means for supplying the release sheet; adhesive supply means for supplying the adhesive; and a device for applying the adhesive supplied from the adhesive supply means to a part of one surface of the release sheet supplied from the release sheet supply means to form the adhesive layer. a pressure-sensitive adhesive layer formed on the release sheet by the pressure-sensitive adhesive layer application means, a hardness adjusting means for adjusting the hardness of the pressure-sensitive adhesive layer so that only a portion of the pressure-sensitive adhesive layer formed on the release sheet by the pressure-sensitive adhesive layer application means penetrates into gaps in the breathable substrate, and a pressing means for pressing the breathable substrate supplied from the substrate supply means against the pressure-sensitive adhesive layer having the hardness adjusted by the hardness adjusting means and for integrating the release sheet and the breathable substrate, the hardness adjusting means including a hardness increasing means for increasing the hardness of a region including the surface of the pressure-sensitive adhesive layer opposite to the surface pressed against the breathable substrate, and the hardness increasing means including a cooling means for cooling the surface of the release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed.
When configured in this manner, the hardness of the adhesive layer applied to the release sheet by the adhesive application means is adjusted by the hardness adjustment means, and then the breathable substrate is pressed against the adhesive layer by the pressing means, thereby laminating the adhesive layer and the release sheet on one side of the breathable substrate and allowing part of the adhesive layer to penetrate into the gaps in the breathable substrate, resulting in a manufacturing device that can produce a breathable product with an integrated structure.

In a fourteenth aspect of the present invention, the breathable product manufacturing apparatus is configured as in the twelfth aspect of the invention, wherein the adhesive is a hot-melt adhesive, and the hardness adjusting means includes a metal roll that engages with the release sheet on which the adhesive layer is formed and cools the release sheet.

When configured in this manner, the manufacturing apparatus includes a metal roll for cooling the release sheet on which the pressure-sensitive adhesive layer is formed.
In a fifteenth aspect of the present invention, the breathable product manufacturing apparatus is configured as in the thirteenth aspect of the invention, wherein the cooling means includes a metal roll that engages with the release sheet on which the pressure-sensitive adhesive layer is formed.
When configured in this manner, the manufacturing apparatus includes a metal roll for cooling the release sheet on which the pressure-sensitive adhesive layer is formed.

As described above, the method for producing a breathable product according to the first aspect of the present invention presses a pressure-sensitive adhesive layer with an adjusted hardness against a breathable substrate, thereby adjusting the extent to which the pressure-sensitive adhesive layer penetrates into the breathable substrate. This allows for the production of a breathable product in which the thickness of the portion of the pressure-sensitive adhesive layer exposed on the surface is optimized. Furthermore, by allowing a portion of the pressure- sensitive adhesive layer to penetrate into the gaps in the breathable substrate, the two are integrated after curing, increasing the bonding strength, thereby reducing adhesive residue when the product is peeled from the attachment target. Furthermore, by adjusting the difference in hardness across the thickness of the pressure-sensitive adhesive layer, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the voids in the breathable substrate, while the increased hardness region does not penetrate into the gaps within the breathable substrate. This allows for the ratio of the pressure-sensitive adhesive layer penetrating the breathable substrate to the portion exposed on the surface of the breathable substrate to be controlled.
In a second aspect of the present invention, the method for producing a breathable product involves pressing a pressure-sensitive adhesive layer with an adjusted hardness against a breathable substrate, thereby adjusting the extent to which the pressure-sensitive adhesive layer penetrates into the breathable substrate. This allows for the production of a breathable product in which the layer thickness of the portion of the pressure-sensitive adhesive layer exposed on the surface is optimized. Furthermore, by allowing a portion of the pressure-sensitive adhesive layer to penetrate into the gaps in the breathable substrate, the two are integrated after curing, increasing the bonding strength, thereby reducing adhesive residue when the breathable product is peeled from the object to which it is attached. Furthermore, the release sheet and the breathable substrate are integrated with the pressure-sensitive adhesive layer having a predetermined thickness on the release sheet, and the surface of the pressure-sensitive adhesive layer is molded by the release sheet, resulting in a flush and smooth surface. This reduces the likelihood of gaps forming between the breathable product and the object when the breathable product is attached to the object.
In addition to the effects of the invention in the second aspect, the method for producing a breathable product in the third aspect of the present invention adjusts the difference in hardness in the thickness direction of the pressure-sensitive adhesive layer so that when the pressure-sensitive adhesive layer is pressed against a breathable substrate, the softened region penetrates into the voids in the breathable substrate, whereas the region of increased hardness does not penetrate into gaps inside the breathable substrate, making it possible to control the ratio of the part of the pressure-sensitive adhesive layer that penetrates into the breathable substrate to the part that is exposed on the surface of the breathable substrate.
In the method for manufacturing a breathable product according to the fourth aspect of the present invention, in addition to the effects of the invention according to the first or third aspect, the layer thickness of the increased hardness region is made uniform, so that when the breathable product is attached to an object to which it is to be attached, gaps are less likely to occur between the object and the breathable product.

In addition to the effects of the first aspect of the invention, the method for producing a breathable product according to the fifth aspect of the present invention makes it possible to adjust the range of hardness increase in the pressure-sensitive adhesive layer by controlling the cooling temperature, cooling time, etc. Thus, the thickness of the exposed part of the pressure-sensitive adhesive layer can be easily optimized by a simple process.

In addition to the effects of the fifth aspect of the present invention, the method for producing a breathable product according to the sixth aspect of the present invention has the advantage that the cooling step can be carried out using a cooling means with a simple configuration, since the pressure-sensitive adhesive layer is cooled via a release sheet. The release sheet makes the surface of the pressure-sensitive adhesive layer flush and smooth, resulting in a breathable product that can be easily attached to an object.

In the method for producing a breathable product according to the seventh aspect of the present invention, in addition to the effects of the second or sixth aspect of the invention, the metal roll can have a large heat capacity and high thermal conductivity, so that by bringing the metal roll into contact with the release sheet, the hardness of a part of the pressure-sensitive adhesive layer can be increased in a short period of time. Therefore, the curing process of the pressure-sensitive adhesive layer can be accelerated, and the production efficiency of the breathable product can be improved.

In addition to the effects of the invention according to any one of the first to seventh aspects, the method for producing a breathable product according to an eighth aspect of the present invention includes adjusting the hardness of the pressure-sensitive adhesive layer beforehand and then pressing the pressure-sensitive adhesive layer against the breathable substrate, so that even in the case of a nonwoven fabric in which the thickness of the exposed part of the pressure-sensitive adhesive layer is likely to be uneven, the thickness of this layer can be made approximately uniform.

The method for producing a breathable product according to a ninth aspect of the present invention not only achieves the effects of the invention according to any one of the first to eighth aspects, but also makes it possible to produce a filter product that can be attached without gaps to an object to which it is to be attached, such as an air vent, because the thickness of the exposed part of the pressure-sensitive adhesive layer is appropriate.

The method for producing a breathable product according to a tenth aspect of the present invention achieves the effects of the invention according to any one of the second, third, and fifth to seventh aspects, and in addition, the pressure-sensitive adhesive layer of the electrostatic filter is formed from a hot-melt pressure-sensitive adhesive, thereby suppressing the deterioration of electrostatic function that occurs when a pressure-sensitive adhesive layer is formed from a conventional solvent-based pressure-sensitive adhesive, and making it possible to produce an electrostatic filter product that has excellent efficiency in filtering ultrafine particles such as PM2.5.
In an eleventh aspect of the present invention, a method for producing a breathable product involves pressing a pressure-sensitive adhesive layer with an adjusted hardness against a breathable substrate, thereby adjusting the extent to which the pressure-sensitive adhesive layer penetrates into the breathable substrate. This allows for a breathable product in which the thickness of the portion of the pressure-sensitive adhesive layer exposed on the surface is optimized. Furthermore, by allowing a portion of the pressure-sensitive adhesive layer to penetrate into the gaps in the breathable substrate, the two are integrated after curing, increasing the bonding strength, thereby reducing adhesive residue when the product is peeled from the attachment target. Furthermore, by adjusting the difference in hardness across the thickness of the pressure-sensitive adhesive layer, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the voids in the breathable substrate, while the increased hardness region does not penetrate into the gaps within the breathable substrate. This allows for control of the ratio of the portion of the pressure-sensitive adhesive layer that penetrates into the breathable substrate to the portion that is exposed on the surface of the breathable substrate.

The breathable product manufacturing apparatus in the 12th aspect of the present invention can provide a manufacturing apparatus capable of manufacturing a breathable product in which the thickness of the pressure-sensitive adhesive layer exposed on the surface of the breathable substrate is appropriate and the surface of the pressure-sensitive adhesive layer is molded flush and smooth by the release sheet.
The breathable product manufacturing apparatus in the 13th aspect of the present invention can provide a manufacturing apparatus capable of manufacturing a breathable product in which the thickness of the pressure-sensitive adhesive layer exposed on the surface of the breathable substrate is appropriate and the surface of the pressure-sensitive adhesive layer is molded flush and smooth by the release sheet.

In addition to the effects of the invention of the twelfth aspect, the breathable product manufacturing apparatus of the present invention has the following advantages: By appropriately selecting the material and size of the metal roll, it is possible to provide high thermal conductivity and large heat capacity, and by cooling the release sheet, it is possible to increase the hardness of the pressure-sensitive adhesive layer in the vicinity thereof in a short period of time. Furthermore, by appropriately selecting the size and rotation speed of the metal roll, it is possible to control the contact area and contact time with the release sheet, and easily adjust the range in which the hardness of the pressure-sensitive adhesive layer is increased. Therefore, by including such a metal roll, it is possible to realize a hardness adjusting means with a simple configuration, high control accuracy, and high reliability. Furthermore, the metal roll enables the pressure-sensitive adhesive layer hardness adjustment process to be performed at a high speed, and therefore it is possible to provide a manufacturing apparatus that can efficiently produce breathable products in which the exposed portions of the pressure-sensitive adhesive layer have a uniform layer thickness.
In a fifteenth aspect of the present invention, in addition to the effects of the thirteenth aspect of the invention, the metal roll can be provided with high thermal conductivity and large heat capacity by appropriately selecting the material and size. Therefore, by cooling the release sheet, it is possible to increase the hardness of the pressure-sensitive adhesive layer in the vicinity thereof in a short period of time. Furthermore, by appropriately selecting the size and rotation speed of the metal roll, the contact area and contact time with the release sheet can be controlled, and the range in which the hardness of the pressure-sensitive adhesive layer is increased can be easily adjusted. Therefore, by including such a metal roll, a hardness adjusting means with a simple configuration and high control accuracy and reliability can be realized. Furthermore, the metal roll can speed up the hardness adjustment process of the pressure-sensitive adhesive layer, so a manufacturing apparatus can be provided that can efficiently produce breathable products in which the exposed portions of the pressure-sensitive adhesive layer have a uniform layer thickness.

1A and 1B are diagrams showing an example of a breathable product according to an embodiment of the present invention, in which (A) is a plan view with a portion omitted, and (B) is a cross-sectional view in which a portion of (A) is enlarged. 1 is a schematic diagram showing an example of a manufacturing apparatus for manufacturing a breathable product according to an embodiment of the present invention. FIG. 3 is an enlarged view of part A in FIG. 2. FIG. 4 is an enlarged cross-sectional view taken along line IV-IV in FIG. 3. FIG. 3 is an enlarged view of part B in FIG. 2. FIG. 6 is an enlarged cross-sectional view taken along line VI-VI in FIG. 5. FIG. 3 is an enlarged view of part C in FIG. 2 . FIG. 8 is an enlarged cross-sectional view taken along line VIII-VIII in FIG. 7.

[Breathable products]
FIG. 1 shows an example of a breathable product according to an embodiment of the present invention, in which (A) is a partially omitted plan view and (B) is an enlarged cross-sectional view of a portion of (A).

Referring to the figure, the breathable product F manufactured by the present invention is, for example, a filter that is attached to an object to filter gas passing through it, and comprises a breathable substrate S1 having gaps on at least one side, and an adhesive layer N formed on part of one side of the breathable substrate S1. In this example, it also includes a release sheet S2 disposed on the surface side of the adhesive layer N. Part of the adhesive layer N penetrates into the gaps in the breathable substrate S1.

The breathable substrate S1 can be made of nonwoven fabric, woven fabric, knitted fabric, or a combination of these. Polypropylene or a propylene-based copolymer is often used as the material for the breathable substrate S1. Furthermore, to impart flame retardancy, an appropriate amount of a fatty acid metal salt such as aluminum stearate can be added to the above synthetic resin raw material, or flame-retardant fibers can be mixed in.

When the breathable product F is a filter, the breathable substrate S1 preferably has a thickness of 0.3 to 15.0 mm and a basis weight of 20 to 200 g/ ^m² . This configuration allows for reliable collection of dust particles in the air while allowing gas to pass through, and provides practical strength. If the thickness is less than 0.3 mm or the basis weight is less than 20 to 200 g/ ^m² , the practical strength may be insufficient and the filter may not exhibit sufficient collection function. If the thickness exceeds 15.0 mm or the basis weight exceeds 200 g/ ^m² , the gas flow resistance increases, and the filter may not be practically useful as an air filter.

It is preferable that the adhesive layer N be made of a solvent-free adhesive such as a hot-melt adhesive or an emulsion-type adhesive.

Conventional hot melt adhesives can be used as the hot melt adhesive, including ethylene vinyl acetate, polyolefin, polyamide, synthetic rubber, acrylic, and polyurethane hot melt adhesives. For filters, synthetic rubber hot melt adhesives are preferred, considering their holding power when attached to an object such as an air vent and their resistance to leaving adhesive residue.

When a synthetic rubber-based hot melt adhesive is used as the hot melt adhesive, the synthetic rubber components contained therein include, for example, styrene-based elastomers such as styrene-butadiene block copolymer, styrene-isoprene block copolymer, and hydrogenated versions of these block copolymers, polyisobutylene, butyl rubber (isobutylene-isoprene copolymer and modified versions of this polymer), olefin-based elastomers such as polybutene, polychloroprene, nitrile rubber, etc. These synthetic rubber components function as elastomers, improving the cohesive strength of the adhesive and ultimately improving its adhesive strength.

The hot melt adhesive may also contain one or more of the ingredients listed below.
- tackifying resins such as rosin-based resins, terpene resins, (hydrogenated) petroleum resins, coumarone-indene-based resins, hydrogenated aromatic copolymers, styrene-based resins, phenol-based resins, and xylene resins;
Plasticizers such as phthalates, adipates, sebacates, other fatty acid esters, paraffins, epoxy polymer plasticizers, phosphates, phosphites, acrylic oligomers, polyisoprene, process oils, naphthenic oils, polyester polyols, polyether polyols, and polyol compounds;
Other polymers such as ethylene-ethyl acrylate copolymer, ethylene-vinyl acetate copolymer, polyvinyl acetate, etc. The above components may be used alone or in combination of two or more. These act as tackifiers for the PSA, and have the function of improving the adhesiveness (adhesion) of the PSA to breathable substrates.

In addition to the above components, other components that can be included in the hot melt adhesive include, for example, mineral oils (synthetic oils) such as petroleum hydrocarbons, vegetable oils, animal oils, paraffins, terpenoids, fatty acids, fatty acid esters, alcohols, honey, crotamiton, etc., which can be used alone or in combination with two or more of the following. All of these components act as softeners for the adhesive, preventing the adhesive strength of the adhesive from decreasing at low temperatures.

The above-mentioned components also function to improve the coatability of the adhesive. For example, depending on the type, molecular weight, and content of the elastomer component that makes up a synthetic rubber-based hot melt adhesive, stringiness and other problems may occur during application of the adhesive. In such cases, adding a softener to the adhesive can effectively prevent stringiness and exhibit good coatability. Furthermore, by including the above-mentioned components in the adhesive, it is possible to reduce the amount of hot melt adhesive residue, i.e., adhesive residue, left on the target object when the electrostatic filter structure of the present invention is peeled off from the target object, such as an air vent, after use.

The release sheet S2 is made of a thin sheet-like material that can hold the applied adhesive on its surface without absorbing it and that also has good release properties for the adhesive. Examples of such materials include polyester films such as polyethylene terephthalate (PET) film and polyolefin films such as polypropylene (PP) film, and the surface of these films may be coated with a release agent such as silicone resin to improve release properties.
[Manufacturing equipment]
Next, a manufacturing apparatus for manufacturing the breathable product according to the present invention will be described.

Figure 2 is a schematic diagram showing an example of a manufacturing apparatus for producing a breathable product according to an embodiment of the present invention.

Referring to the figure, the manufacturing apparatus P of the present invention includes a substrate supply means for supplying a breathable substrate S1, a release sheet supply means for supplying a release sheet S2, an adhesive supply means for supplying an adhesive M, an adhesive application means for applying the adhesive M supplied from the adhesive supply means to a portion of one side of the release sheet S2 supplied from the release sheet supply means to form an adhesive layer, a hardness adjustment means for adjusting the hardness of the adhesive layer so that only a portion of the adhesive layer penetrates into the gaps in the breathable substrate S1, and a pressing means for pressing the breathable substrate S1 supplied from the substrate supply means against the adhesive layer of the adjusted hardness.

In this example, for example, the breathable substrate S1 is a nonwoven fabric, the release sheet S2 is a PET film, and the adhesive M is a hot-melt adhesive that hardens at room temperature and softens when heated.

In the manufacturing apparatus P of this example, the breathable substrate S1 supply means includes supply rolls 10 and 11 for adjusting the feed speed of the breathable substrate S1 while supplying it, and transport rolls 12, 13, and 14 for transporting the breathable substrate S1. The adhesive M supply means includes an adhesive supply roll 2 and an auxiliary roll 1 for storing and dispensing adhesive M. The adhesive application means includes an application roll 3 and a backup roll 4 for applying adhesive M supplied from the adhesive supply roll 2 to form an adhesive layer N of a predetermined pattern. The hardness adjustment means includes a metal roll 7 that contacts the surface of the release sheet S2 opposite the surface on which the adhesive layer N is formed. The pressing means includes nip rolls 5 and 6 for laminating and pressing the breathable substrate S1 supplied from the breathable substrate supply means and the release sheet S2, the hardness of which has been adjusted, to bond them together. Note that a known mechanism can be used for the release sheet S2 supply means, and illustrations are omitted.

The auxiliary roll 1, adhesive supply roll 2, applicator roll 3, and backup roll 4 are arranged adjacent to each other and are configured to rotate in unison. Molten adhesive M is stored above the joint between the adhesive supply roll 2 and auxiliary roll 1. When the adhesive supply roll 2 is rotated, the adhesive M adhering to its surface is transferred to the surface of the applicator roll 3 in contact with it. The amount of transferred adhesive M can be controlled by adjusting the gap between the adhesive supply roll 2 and auxiliary roll 1.

The applicator roll 3 can be a known printing roll, such as a gravure roll or letterpress roll. Furthermore, by making the surface of the applicator roll 3 a metal surface, releasability is improved, facilitating the transfer of the adhesive M from the applicator roll 3 to the release sheet S2.

When a release sheet S2 is passed between an applicator roll 3, on whose surface adhesive M transferred from an adhesive supply roll 2 is adhered, and a backup roll 4, the adhesive M is applied to one side of the release sheet S2, forming an adhesive layer N. The adhesive layer N can also be in the form of letters, designs, etc.

The metal roll 7, which is brought into contact with the surface of the release sheet S2 opposite to the surface on which the pressure-sensitive adhesive layer N is formed, is made of a metal with high thermal conductivity such as copper, brass, aluminum, iron, or stainless steel. The heat capacity can be set by appropriately selecting the material and outer dimensions. The contact area between the metal roll 7 and the release sheet S2 can be set by the diameter of the metal roll 7, the position of the metal roll 7 relative to the path of the release sheet S2, etc. The metal roll 7 may be equipped with an appropriate heat dissipation mechanism or cooling mechanism. The metal roll 7 can also have a tensor function that applies tension to the release sheet.
[Manufacturing method]
Next, a method for producing a breathable product according to the present invention using the above-mentioned production apparatus P will be described.

Figure 3 is an enlarged view of part A in Figure 2. Figure 4 is an enlarged cross-sectional view taken along line IV-IV in Figure 3. Figure 5 is an enlarged view of part B in Figure 2. Figure 6 is an enlarged cross-sectional view taken along line VI-VI in Figure 5. Figure 7 is an enlarged view of part C in Figure 2. Figure 8 is an enlarged cross-sectional view taken along line VIII-VIII in Figure 7.

With reference to these figures, the manufacturing method of the present invention comprises a substrate preparation step of preparing a breathable substrate S1 having gaps on at least one side; a hardness adjustment step of preparing an adhesive layer to be formed on part of one side and adjusting the hardness of the adhesive layer so that only part of the adhesive layer penetrates into the gaps in the breathable substrate S1; and a pressing step of pressing the adhesive layer with the adjusted hardness against the breathable substrate S1.

In this example, the substrate preparation step is carried out by a means for supplying the breathable substrate S1. The adhesive layer preparation step is carried out by applying adhesive M to one side of the release sheet S2 using an applicator roll 3. The hardness adjustment step is carried out by contacting a metal roll 7 with the opposite side of the release sheet S2 on which the adhesive layer has been formed. The pressing step is carried out by passing the surface of the release sheet S2 on which the adhesive layer has been formed and the breathable substrate S1 between nip rolls 5 and 6 while they are facing each other.

The manufacturing method for the breathable product F in this example is described in detail below.

Referring to Figure 2, in manufacturing equipment P, by rotating adhesive supply roll 2, molten adhesive M stored above the joint between adhesive supply roll 2 and auxiliary roll 1 is transferred to the surface of applicator roll 3, which is in contact with adhesive supply roll 2.

Then, as shown in Figure 3, the release sheet S2 supplied from the supply means is passed between the applicator roll 3 and the backup roll 4, whereby the adhesive M is applied in a predetermined pattern to one side of the release sheet S2, and as shown in Figure 4, an adhesive layer N in a predetermined pattern is formed on the release sheet S2.

Next, the release sheet S2 with the adhesive layer N formed thereon is transported to the position of the metal roll 7, and as shown in FIG. 5, the surface on which the adhesive layer N is not formed is engaged with the metal roll 7. The metal roll 7 is configured to be cooler than the temperature of the adhesive layer N, have excellent thermal conductivity, and have sufficient heat capacity. Therefore, as shown in FIG. 6, the adhesive layer N in a softened state on the release sheet S2 is cooled by the metal roll 7 through the release sheet S2, and the region of the adhesive layer N near the release sheet S2 becomes an increased hardness region N1, where the hardness has increased due to the temperature drop. In contrast, the surface region of the adhesive layer N away from the release sheet S2 remains in a softened state region N2 that has fluidity.

Since the contact between the release sheet S2 and the metal roll 7 is almost uniform everywhere, it is believed that the temperature drop in the adhesive layer N caused by this contact is almost uniform. Therefore, the layer thickness of the increased hardness region N1 in the adhesive layer N is almost uniform.

In Figure 6, for ease of explanation, the boundary between the two regions, the increased hardness region N1 and the softened state region N2, is shown by a dashed line. However, in reality, the hardness changes continuously from the region of the adhesive layer N near the release sheet S2 to the surface region of the adhesive layer N away from the release sheet S2.

Furthermore, the degree and range of hardness increase of the adhesive layer N can be controlled by adjusting the temperature, thermal conductivity, heat capacity, contact area and contact time with the release sheet S2 of the metal roll 7, making it possible to easily adjust the layer thickness of the hardness increase region N1.

In this way, the release sheet S2, for which the pressure-sensitive adhesive layer N has undergone the hardness adjustment process, is transported to the position of nip rolls 5 and 6. Meanwhile, the breathable substrate S1 is also transported to the position of nip rolls 5 and 6 by supply rolls 10 and 11 and transport rolls 12, 13, and 14. At this time, the transport speeds of the breathable substrate S1 and release sheet S2 are controlled so that they match at the position of nip rolls 5 and 6.

The breathable substrate S1 and release sheet S2 are supplied to nip rolls 5 and 6, and as shown in Figure 7, the breathable substrate S1 faces the surface of the release sheet S2 on which the adhesive layer N is formed, and the two are passed between the nip rolls 5 and 6. This presses the adhesive layer N on the release sheet S2 against the breathable substrate S1, producing a breathable product F in which the two are integrated.

When the adhesive layer N is pressed against the breathable substrate S1, as shown in Figure 8, the softened region N2 located on the surface side of the adhesive layer N penetrates into the voids in the breathable substrate S1 due to its fluidity. On the other hand, the increased hardness region N1 in the adhesive layer N near the release sheet S2 does not penetrate into the gaps inside the breathable substrate S1 due to its low fluidity, and remains on the surface of the breathable substrate S1.

The portion of the adhesive layer N that penetrates into the breathable substrate S1 forms an anchor layer R after curing, providing excellent bonding strength to the adhesive layer N. Therefore, when the release sheet S2 is peeled off during product use, there is no risk of adhesive residue remaining on the surface of the adhesive layer N.

On the other hand, the increased hardness region N1 of the adhesive layer N forms an exposed layer Q exposed on the surface of the breathable substrate S1 after curing. By adjusting the layer thickness of the increased hardness region N1 to a substantially constant value, the layer thickness of the exposed layer Q can also be formed appropriately and approximately uniformly. This reduces the likelihood of gaps forming between the breathable product F and the object when it is attached to the object. Furthermore, if the softened region N2, which is the portion of the adhesive layer N that penetrates into the breathable substrate S1, has a significantly low viscosity or if the voids in the breathable substrate S1 are large, the softened region N2 may penetrate more than expected into the voids in the breathable substrate S1 before curing, resulting in the adhesive layer N penetrating the surface of the breathable substrate S1 opposite the surface on which the exposed layer Q is formed. If such penetration occurs, when the breathable substrate S1 and the release sheet S2 are laminated and pressed together and passed between nip rolls 5 and 6, problems such as the pressure-sensitive adhesive layer N that has penetrated the breathable substrate S1 may adhere to the nip roll 6, causing the laminate of the breathable substrate S1 and the release sheet S2 to wrap around the nip roll 6, or the breathable substrate S1 alone may adhere to and be pulled by the nip roll 6, causing the laminate of the breathable substrate S1 and the release sheet S2 to separate, or a part of the breathable substrate S1 may be pulled toward the nip roll 6, causing the breathable substrate S1 to tear (hereinafter referred to as a first problem) may occur. Furthermore, even if the substrate passes between the nip rolls 5 and 6, if a transport roll (not shown) is used for transport to the next process, a problem (hereinafter referred to as a second problem) may occur due to the breathable substrate S1 adhering to the transport roll, similar to the adhesive layer N adhering to the nip roll 6 mentioned above. To prevent these first and second problems, the softened region N2 can be cooled and hardened before the pressure-sensitive adhesive layer N penetrates the surface of the breathable substrate S1 opposite the surface on which the exposed layer Q is formed. To achieve this, for example, a cooling mechanism can be provided on the nip roll 6 itself, which contacts the breathable substrate S1, to address the first problem. Alternatively, a cooling mechanism can be provided between the nip roll 6 and the transport roll in the next process to cool the surface of the breathable substrate S1 opposite the surface on which the exposed layer Q is formed, to address the second problem. However, even when providing such a cooling mechanism, it is preferable to balance the degree of cooling so as not to inhibit penetration of the pressure-sensitive adhesive layer N into the breathable substrate S1, thereby preventing the formation of the anchor layer R.

The breathable product F manufactured as described above is cut to the required size and commercialized as a filter product with a release sheet, which is then sold. To use the product, the release sheet S2 is peeled off at the work site, and the breathable substrate S1, made of nonwoven fabric or the like, is attached to the target object using the adhesive layer N.

In this example, the pressure-sensitive adhesive layer N is not formed over the entire surface of the breathable substrate S1, but is formed partially by pattern coating. When the pressure-sensitive adhesive M is a hot-melt pressure-sensitive adhesive, the preferred application amount is 20 to 50 g/m ² , more preferably 25 to 35 g/m ^2. The preferred application area of the hot-melt pressure-sensitive adhesive is usually in the range of 40 to 80% of the entire breathable substrate S1. However, the above numerical values can be changed as appropriate depending on the application and size of the breathable product F.
[Other embodiments]
The embodiments of the present invention are not limited to those described above.

In addition to nonwoven fabric, breathable substrates may also be woven fabric, knitted fabric, or a combination of these.

Adhesives that can be used include hot melt adhesives, emulsion adhesives, UV-curable adhesives, etc.

In addition to using a metal roll, the hardness of the adhesive layer can be adjusted by contacting a belt that moves at the same speed as the release sheet's conveyance speed with the release sheet on the side of the release sheet opposite the side on which the adhesive layer is formed. Alternatively, this can be done by spraying cooling gas onto the opposite side. If an ultraviolet-curing adhesive is used for the adhesive layer, the hardness of the adhesive layer can be adjusted by irradiating ultraviolet light from the side of the release sheet opposite the side on which the adhesive layer is formed.

The adhesive supply means can also be a tank that stores the adhesive in a fluid state, and the adhesive can be supplied directly from this tank to the adhesive supply roll.

Adhesive application methods include roll coating using an application roll, as well as spray coating, inkjet coating, die coating, screen printing, etc.

The breathable products manufactured by this invention can be widely used in household appliances such as kitchen and kitchen range hoods, air conditioners, air purifiers, and ventilation fans, as well as in air filter products for indoor and outdoor vents and ventilation points in industrial equipment, and as constituent materials for breathable hygiene products such as masks, diapers, sheets, and clothing.

The present invention can also be applied to the manufacture of electrostatic filters. Electrostatic filters use electrostatic force to efficiently capture and remove fine particles from gas. Their use has expanded in recent years due to their ability to effectively remove ultrafine particles known as PM2.5, which have a particle diameter of 2.5 μm or less and are feared to have a serious impact on the human respiratory system.

When manufacturing an electrostatic filter according to the present invention, an electrostatically active nonwoven fabric is used as the breathable substrate. Examples of such nonwoven fabrics include a combination of polyester fibers (PET fibers) and modacrylic fibers that have been electrically charged; polypropylene nonwoven fabric that has been electrically charged by corona discharge treatment; nonwoven fabric containing wool fibers that has been resin-treated and then tanned to be electrically charged; and core-sheath composite fibers in which the surface of polypropylene resin is coated with polyethylene resin, with the fiber surface polarized and charged by generating a high DC electric field using an applied electrode. These are all well-known electrostatic filters that can be used.

Furthermore, when manufacturing an electrostatic filter based on this invention, the use of a hot-melt adhesive as the adhesive improves the capture effect of ultrafine particles such as PM2.5 compared to when conventional solvent-based adhesives are used.

The details of the mechanism by which the use of hot-melt adhesives improves PM2.5 collection efficiency compared to conventional solvent-based adhesives are unknown. One hypothesis is that conventional adhesives are diluted with a solvent such as ethyl acetate before use, and when this is applied to an electrostatic filter, static electricity is generated at the interface between the adhesive and the electrostatic filter, or within the adhesive, due to the flow during application. This cancels out the charge on the electrostatic filter, thereby reducing the PM2.5 collection efficiency of the electrostatic filter structure.

Therefore, based on the above speculation, it is thought that the reason why the use of hot melt adhesives improves the PM2.5 collection efficiency is because the adhesive flows less when pressed against a breathable substrate, and because it does not contain solvents, static electricity is less likely to occur at the interface with the breathable substrate or within the adhesive layer.

In addition, the present invention can be applied in a variety of ways and modified as needed to suit the circumstances of implementation.

The present invention makes it possible to produce breathable products with a uniform thickness of adhesive layer formed on a breathable substrate such as nonwoven fabric, making it possible to provide air filter products that attach well to range hoods, air conditioners, air purifiers, ventilation fans, vents, etc., leaving little adhesive residue, as well as materials for breathable hygiene products.

Claims (15)

A method for producing a breathable product (F), comprising:
A substrate preparation step of preparing an air-permeable substrate (S1) having a gap on at least one side;
a hardness adjusting step of preparing a pressure-sensitive adhesive layer (N) to be formed on a portion of the one surface side and adjusting the hardness of the pressure-sensitive adhesive layer so that only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate;
a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness onto the breathable substrate after the hardness adjusting step,
the hardness adjusting step includes a hardness increasing step of increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate,
the pressure-sensitive adhesive layer having the adjusted hardness has an increased hardness region formed on a surface opposite to a surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region;
The pressure-sensitive adhesive layer is made of a hot-melt pressure-sensitive adhesive (M),
The hot melt adhesive has an application amount of 20 to 50 g/ ^m2 and an application area of 40 to 80% of the entire breathable substrate. A method for producing a breathable product (F) in which a pressure-sensitive adhesive layer (N) is formed on one side of a breathable substrate (S1) having a gap on at least one side, and a release sheet (S2) is arranged on the surface side of the pressure-sensitive adhesive layer, and the release sheet is peeled off, and the breathable substrate portion is attached to an object to be attached using the pressure-sensitive adhesive layer,
preparing a pressure-sensitive adhesive layer to be formed on a portion of the one surface side, and forming the pressure-sensitive adhesive layer on the release sheet;
a hardness adjusting step of adjusting the hardness of the pressure-sensitive adhesive layer formed on the release sheet so that only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate;
a substrate preparation step of preparing the breathable substrate;
a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness onto the breathable substrate after the hardness adjusting step,
the hardness adjusting step includes a hardness increasing step of increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate,
the hardness increasing step includes a cooling step of cooling the surface of the release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed,
The method for producing a breathable product includes a step of pressing the pressure-sensitive adhesive layer with the adjusted hardness of the release sheet onto the breathable substrate to integrate the release sheet and the breathable substrate. The method for manufacturing a breathable product described in claim 2, wherein the pressure-sensitive adhesive layer with adjusted hardness has an increased hardness region formed on the surface opposite to the surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state. The method for manufacturing a breathable product according to claim 1 or 3, wherein the pressure-sensitive adhesive layer with adjusted hardness has a hardness that changes continuously in the layer direction from the increased hardness region to the softened state region. The pressure-sensitive adhesive layer is made of a hot-melt pressure-sensitive adhesive (M),
The method for producing a breathable product according to claim 1 , wherein the hardness increasing step includes a cooling step of cooling a region of the softened pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate. The method for producing a breathable product according to claim 5, wherein the cooling step includes preparing a release sheet (S2) having an adhesive layer made of a softened hot-melt adhesive formed on one side thereof, and cooling the surface of the release sheet opposite the surface on which the adhesive layer is formed. The method for manufacturing a breathable product according to claim 2 or 6, wherein the step of cooling the release sheet includes a step of engaging the release sheet with a metal roll (7) that has a temperature lower than that of the adhesive layer on the release sheet. The method for manufacturing a breathable product according to any one of claims 1 to 7, wherein the breathable substrate is made of nonwoven fabric. The method for manufacturing a breathable product according to any one of claims 1 to 8, wherein the breathable product is a filter. The method for manufacturing a breathable product according to any one of claims 2, 3, and 5 to 7, wherein the breathable product is an electrostatic filter. A method for producing a breathable product (F) in which a pressure-sensitive adhesive layer (N) is formed on one side of a breathable substrate (S1) having a gap on at least one side, and a release sheet (S2) is arranged on the surface side of the pressure-sensitive adhesive layer, and the release sheet is peeled off, and the breathable substrate portion is attached to an object to be attached using the pressure-sensitive adhesive layer,
preparing a pressure-sensitive adhesive layer to be formed on a portion of the one surface side, and forming the pressure-sensitive adhesive layer on the release sheet;
a hardness adjusting step of adjusting the hardness of the pressure-sensitive adhesive layer formed on the release sheet so that only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate;
a substrate preparation step of preparing the breathable substrate;
a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness onto the breathable substrate after the hardness adjusting step,
the hardness adjusting step includes a hardness increasing step of increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate,
the pressure-sensitive adhesive layer having the adjusted hardness has an increased hardness region formed on a surface opposite to a surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region;
The method for producing a breathable product, wherein the hardness increasing step includes a cooling step of cooling the surface of the release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed. A manufacturing apparatus (P) for manufacturing a breathable product, in which a pressure-sensitive adhesive layer (N) is formed on one side of a breathable substrate (S1) having a gap on at least one side, and a release sheet (S2) is arranged on the surface side of the pressure-sensitive adhesive layer, and the release sheet is peeled off and the breathable substrate portion is attached to an object to be attached using the pressure-sensitive adhesive layer,
a substrate supply means (10 to 14) for supplying the breathable substrate;
a release sheet supplying means for supplying a release sheet;
adhesive supply means (1, 2) for supplying an adhesive (M);
an adhesive application means (3, 4) for applying the adhesive supplied from the adhesive supply means to a part of one side of the release sheet supplied from the release sheet supply means to form an adhesive layer;
a hardness adjusting means (7) for adjusting the hardness of the adhesive layer so that only a portion of the adhesive layer formed on the release sheet by the adhesive application means penetrates into the gaps in the breathable substrate;
a pressing means (5, 6) for pressing the breathable substrate supplied from the substrate supply means onto a pressure-sensitive adhesive layer having a hardness adjusted by the hardness adjusting means,
the hardness adjusting means includes a hardness increasing means for increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate,
the pressure-sensitive adhesive layer having the adjusted hardness has an increased hardness region formed on a surface opposite to a surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region;
The hardness increasing means comprises a cooling means for cooling the side of the release sheet opposite to the side on which the pressure-sensitive adhesive layer is formed. A manufacturing apparatus (P) for manufacturing a breathable product, in which a pressure-sensitive adhesive layer (N) is formed on one side of a breathable substrate (S1) having a gap on at least one side, and a release sheet (S2) is arranged on the surface side of the pressure-sensitive adhesive layer, and the release sheet is peeled off and the breathable substrate portion is attached to an object to be attached using the pressure-sensitive adhesive layer,
a substrate supply means (10 to 14) for supplying the breathable substrate;
a release sheet supplying means for supplying a release sheet;
adhesive supply means (1, 2) for supplying an adhesive (M);
an adhesive application means (3, 4) for applying the adhesive supplied from the adhesive supply means to a part of one side of the release sheet supplied from the release sheet supply means to form an adhesive layer;
a hardness adjusting means (7) for adjusting the hardness of the adhesive layer so that only a portion of the adhesive layer formed on the release sheet by the adhesive application means penetrates into the gaps in the breathable substrate;
and pressing means (5, 6) for pressing the breathable substrate supplied from the substrate supply means against a pressure-sensitive adhesive layer having a hardness adjusted by the hardness adjusting means, and for integrating the release sheet and the breathable substrate,
the hardness adjusting means includes a hardness increasing means for increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate,
The hardness increasing means comprises a cooling means for cooling the side of the release sheet opposite to the side on which the pressure-sensitive adhesive layer is formed. the pressure-sensitive adhesive is a hot-melt pressure-sensitive adhesive,
13. The breathable product manufacturing apparatus according to claim 12, wherein the hardness adjusting means includes a metal roll (7) that engages with the release sheet on which the pressure-sensitive adhesive layer is formed and cools the release sheet. The breathable product manufacturing apparatus of claim 13, wherein the cooling means includes a metal roll (7) that engages with the release sheet on which the adhesive layer is formed.