JP2000316772A - Composite sheet and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prepare a composite sheet which is uniformly distributed with many continuous fibers on a base layer. SOLUTION: The composite sheet used as a sheet 1 for cleaning, or the like, is formed by joining the base layer 7 and the continuous fibers 8a formed as groups at joint lines 5. The joint lines 5 consist of the first joint lines 5A formed on one side of an axis C-C bisecting the width of the groups of the continuous fibers 8a and the second joint lines 5B formed on another one side. The first and second joint lines 5A and 5B intersect diagonally with the groups of the continuous fibers 8a so as to extend toward the axis C-C and intersect diagonally with each other.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bulky composite sheet composed of a base layer and a surface layer composed of a continuous fiber group, and more particularly to a disposable composite sheet for wiping dust, such as floors, walls and windows. The present invention relates to a sheet, a disposable sheet for absorbing body fluid and the like, and a sheet suitable for use as a cushioning sheet.

[0002]

8 and 9 are perspective views of a conventional example of a composite sheet 101 in which continuous fibers are joined to a base sheet such as a nonwoven fabric. FIG. 10 is a perspective view of a holder 103 to which the composite sheet 101 is attached. FIG. Such a composite sheet 101 and holder 103 are disclosed in Japanese Patent Application Laid-Open No. Hei 9-14987.
No. 3 discloses this. When the floor is rubbed while holding the holder 103 in a hand, dust can be collected on the upper surface of the composite sheet 101 shown in FIGS. In the composite sheet 101, the base sheet 107 and a large number of continuous fibers
05 are integrated. Such a composite sheet 101
Can be manufactured by superposing the base sheet 107 and the continuous fiber 108 and supplying them between a pair of heated embossing rolls. However, as indicated by the joining line 105 in FIG.
When there are many 31, in the manufacturing process of the composite sheet 101,
In the vicinity of the intersection 131, there is a problem that the distribution of the continuous fibers 108 tends to be uneven.

[0003] In the composite sheet 101 of FIG.
08 and the base sheet 107 are supplied to the embossing roll in the direction of the arrow P, and the joining lines 105 are sequentially formed in the direction of the arrow Q. When the continuous fibers 108 are formed in the direction of the arrow Q, that is, outside the base sheet 107 in the width direction. There is a problem that it is difficult to make the distribution of the continuous fibers 108 uniform in the width direction of the composite sheet 101.

[0004]

SUMMARY OF THE INVENTION Therefore, the present invention
It is an object of the present invention to provide a bulky composite sheet capable of solving the above-mentioned problems of the prior art and a method for producing the same.

[0005]

In order to solve the above problems,
One of the objects of the present invention is that the composite sheet is
A base layer having a longitudinal axis and having an upper surface and a lower surface;
It is composed of a continuous fiber group extending along the axis, has a predetermined width defined between opposing side edges extending along the axis, and has a plurality of bonding lines extending in a direction intersecting with the axis. It is a composite sheet including a surface layer joined to at least one surface of a lower surface.

The features of the present invention in such a composite sheet are as follows.

[0007] The joining line is formed by a plurality of first limbs formed in one side area of the shaft that divides the width into two in the surface layer.
It comprises a joining line and a plurality of second joining lines formed on the other side area. The first joint line and the second joint line obliquely intersect the continuous fiber group of the surface layer so as to intersect with each other when extending toward the axis.

Another object of the present invention for solving the above-mentioned problem is as follows.

A method of manufacturing a composite sheet having a longitudinal axis, the method comprising: a base layer web having an upper surface and a lower surface; a group of continuous fibers extending along the axis; The composite sheet web is constituted by a surface layer web having a predetermined width defined between opposed side edges extending, and the surface layer web and the base layer web are continuously supplied in the axial direction. Superimposing the surface layer web on at least one surface of the base layer web, and joining the base layer web and the surface layer web by a plurality of joining lines extending in a direction intersecting the axis.

In this manufacturing method, the present invention is characterized in that the tow for the continuous fiber group of the surface layer web is spread on at least one surface of the base layer web and expanded to a required width. A point and the joining line
A plurality of first joining lines formed in one side area of the shaft that divides the width of the surface web into two equal parts, and a plurality of second joining lines formed in the other side area; The first joining line and the second joining line obliquely intersect with the continuous fiber group of the surface web so as to intersect with each other when extending toward the axis, and the base layer web and the surface web are connected to each other. When supplying in the axial direction, the first bonding line and the second bonding line are sequentially formed from the axis toward the outside in the width direction of the surface layer web.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The details of the composite sheet and the method for producing the same according to the present invention will be described below with reference to the accompanying drawings.

FIGS. 1 and 2 are a perspective view of a floor cleaning sheet 1, which is an example of a composite sheet, and a cross-sectional view taken along the line II-II. The cleaning sheet 1 has a base layer 7 made of a thermoplastic non-woven fabric.
A surface layer 8 composed of a large number of thermoplastic continuous fibers 8a is welded to a plurality of joining lines 5 extending from a longitudinal axis CC (see FIG. 3) to both side edges 8c on the upper surface of the sheet 1. 10, the side edges 9 of the base layer 7 are fixed to the holder 103 of FIG. 10, and dust on the floor can be wiped off by the continuous fibers 8 a of the surface layer 8. This sheet 1 can also be used by rubbing it by hand. Continuous fiber 8a of surface layer 8
Extend between both side edges 9 of the base layer 7 and extend parallel to each other in the length direction of the base layer 7 indicated by an arrow A. Since the continuous fibers 8a of the surface layer 8 are melted and solidified at the bonding line 5 by heating and pressing, the fiber form has almost lost its fiber form, and the compressed grooves are defined. The raised area 8b is defined.
It is preferable that the height of the arc-shaped raised area is at least three times the total thickness of the joint line 5 (the bottom of the compressed groove) and the base layer 7. Such a surface layer 8 exhibits not only a three-dimensional appearance, but also excellent bulkiness, elasticity and compressibility, and it goes without saying that such properties are much higher than those of the base layer. Such a cleaning sheet 1 includes continuous fibers 8a of the surface layer 8.
To the floor and move it in the direction of arrow A or in the direction of arrow B perpendicular to arrow A, the continuous fibers 8a forming an arc rub the floor, and dust can be taken in between the continuous fibers 8a and 8a. . The continuous fibers 8a are welded to both ends of the base layer 7 in the direction of arrow A at a joining line 15. However, the joining line 15 is not always necessary.

FIG. 3 is a plan view of the cleaning sheet 1.
The individual continuous fibers 8a of the surface layer 8 are schematically and widely drawn. The surface layer 8 has its width approximately bisected by the axis CC, and the joining line 5 is located on one side of the axis CC above the figure.
A plurality of first joining lines 5A are formed, and a second joining line 5B among the joining lines 5 is provided on the other side below the figure.
Are formed. The plurality of first joining lines 5A are formed so as to be parallel to each other and at equal intervals, and the same applies to the second joining lines 5B. The first and second joining lines 5A and 5B extend obliquely and intersect with the continuous fiber 8a of the surface layer 8 and extend along the axis C.
When each is extended toward -C, it is inclined with respect to the continuous fibers 8a of the surface layer 8 so that they can cross each other. However, in the illustrated example, the first and second joining lines 5A, 5A
B has already crossed on axis CC. The first and second joining lines 5A and 5B extend to the side edge 9 of the base layer 7 at the same angle with respect to the axis CC, in other words, with the continuous fiber 8a of the surface layer 8. ing. The first joining line 5A and the second joining line 5B have first ends 11A and 11B located on the axis CC and second ends 12A and 12B located near the side edge 9.

FIG. 3 shows an imaginary line H extending in the width direction of the cleaning sheet 1 perpendicularly to the axis CC. First,
The two joining lines 5A, 5B are the first of the first and second joining lines 5A, 5B.
The imaginary line H drawn so as to intersect with the ends 11A and 11B is also formed so as to intersect with the second ends 12A and 12B of the other first and second joining lines parallel to the joining lines 5A and 5B.
Speaking in the illustrated example, virtual line H ₁ intersecting the first end 11A of the first joining line 5A is intersects the second end 12A of the next first joining line 5A skip immediately first joining line 5A next ing.
Continuous fiber 8 of surface layer 8 extending in the direction of arrow A in parallel with each other
a is the first joint line 5A or the second joint line 5
B joins the base layer 7 and does not fall off the layer 7.

The size of the cleaning sheet 1 is exceptional.
Although there is no limitation, preferably, the length of the base layer 7 is 5 to 2
00 cm and a width in the range of 5 to 50 cm. Base layer 7
Include woven, non-woven and thermoplastic
Uses dimensionally stable materials such as conductive synthetic resin films
Examples of preferred non-woven fabrics include polyethylene
Spunbon using composite fiber of ren and polyester
Woven and point-bonded nonwovens.
You. Non-woven fabrics and films have a basis weight of 5-200 g / m ²Nomo
It is preferred to use

As the continuous fibers 8a of the surface layer 8, continuous fibers such as polyethylene, polypropylene, nylon, polyester and rayon can be used. As an example of a preferred continuous fiber 8a, the continuous fiber 8a is formed by a known method.
The tow, which is a bundle of a, is opened and expanded to a required width. Tow is commercially available and is a rope-like bundle of continuous polymer filaments. Filament is 1-20d
Are available. When the continuous fiber 8a of the surface layer 8 is crimped, the continuous fiber 8a is bulky and flexible, so that it is suitable for lightly wiping the floor dust.
Moreover, it is excellent in that the wiped trash can be reliably held. The number of crimps of the crimped continuous fiber 8a is preferably 5 to 25 peaks / 2.54 cm.
The basis weight of the continuous fibers 8a of the surface layer 8 is 20 to 500 g / m ^2.
Is preferably within the range. The continuous fiber 8a can be subjected to an oil treatment or a hydrophilic treatment to improve the performance of wiping floor dust and moisture.

The joining line 5 is preferably a line in which the base layer 7 and the continuous fibers 8a of the surface layer 8 are welded together.
10 to 80 °, more preferably 15 to 75 ° with respect to C
Can be inclined in the range of Although there is no particular limitation on the width of the joining line 5, it is generally preferable that the width is in the range of 0.5 to 10 mm.

In the illustrated example, the continuous fibers 8a of the surface layer 8, which are bonded only to the upper surface of the base layer 7, can also be bonded to the lower surface of the base layer 7. When the continuous fibers 8a of the surface layer 8 are bonded to the upper and lower surfaces of the base layer 7, it is preferable that the shape and position of the bonding line 5 be matched on the upper and lower surfaces.

FIGS. 4 to 6 are views similar to FIG. 2 illustrating an embodiment of the present invention. In FIG. Cleaning sheet 1 of 4, the first joining line 5A, the first end 11A of the 5B, the first joining line 5A of the virtual line _{H 1} Gasugu next intersecting 11B, the second 5B
Intersects ends 12A and 12B.

Each of the joining lines 5 of the cleaning sheet 1 shown in FIG. 5 is relatively short, and the first joining line 5A above the axis CC is the first end 11A on the axis CC. And a relatively short first joining line 5D having a second end 12A at the side edge 9 of the base layer 7, and a second joining line below the axis CC. 5B is the first on the axis CC.
A second joining line 5E having an end 11B and a second joining line 5F having a second end 12B at the side edge 9 of the base layer 7 are included.
In the first and second joining lines 5A and 5B in FIG.
A and 11B are ends of each joint line near the axis CC,
The second ends 12A and 12B are one ends near the side edge 9.
First end 11A of 5C or 5D of first joining line 5A
Virtual line _{H 1} intersecting the intersects immediately second end 12A of 5C or 5D of the first joining line 5A neighbors. The same applies to the relationship between the second joining line 5B and the virtual line H. The continuous fibers 8a of the surface layer 8 include first bonding lines 5A including 5C and 5D, and 5E,
It is bonded to the base layer 7 by any of the second bonding lines 5B including 5F and does not fall off from the layer 7.

The joining line 5 of the cleaning sheet 1 shown in FIG.
-C to the side edge 8c,
The first ends 11A and 11B of the two joining lines 5A and 5B are connected to the axis C-
There is no intersection on C. However, the first and second joint lines 5A
And 5B are inclined with respect to the axis CC so as to intersect each other when extended in the direction of the axis CC. 1st joining line 5
Virtual line _{H 1} intersecting the first end 11A of A, immediately adjacent the first
It crosses the second end 12A of the joining line 5A. The same applies to the relationship between the second joining line 5B and the virtual line H.

The cleaning sheet 1 having the bonding lines 5 illustrated in FIGS. 3 to 6 is obtained by laminating a web of the base layer 7 and a web of the surface layer 8 expanded to a required width to form a pair of heated rotating embosses. It can be manufactured by continuously supplying between rolls. On at least one of the pair of embossing rolls, an embossing projection corresponding to the joining line 5 is formed, and the joining line 5 is applied to the web of the surface layer 8 by the axis CC.
The embossing roll is rotated so that the embossing rolls are sequentially formed from the base layer 7 toward the side edge 9 of the web. In this way, even when the web of the surface layer 8 is supplied to the embossing roll in a state where the number of fibers is relatively large at the center in the width direction, the joining line 5 moves from the axis CC to the side edge 9. Along with the formation, the web of the surface layer 8 spreads with a uniform thickness with respect to the web of the base layer 7.

FIG. 7 is a partially enlarged view of FIG. 3, and illustrates a state where the joining line 5 and the virtual line H intersect. The joining length L along the virtual line H at an arbitrary position in the length direction (A direction) of the cleaning sheet 1 is the sum of the lengths of the respective portions where the joining line 5 and the virtual line H intersect, For example, the virtual line H ₁
Junction length _{L 1} of about _is L 1 = a + b + c + d, junction length _{L 2} of the imaginary line _{H 2 is} L 2 = a +
d + e. Depending on the shape of the joining line 5, the value of L may change depending on the position of the imaginary line H on the cleaning sheet 1. In the manufacturing method of the cleaning sheet 1 according to the present invention, the value of L changes. The shape and position of the joining line 5 are adjusted so that the ratio of the maximum value to the minimum value is 2 or less. For example, as illustrated in FIGS. 3 to 6, when the imaginary line H intersects the first ends 11A and 11B of the joining line 5, the imaginary line H also intersects with the second ends 12A and 12B of the other joining lines 5 or other portions. I do. In this way, when the web of the base layer 7 and the web of the surface layer 8 which are superimposed are supplied to the embossing roll, the web of the base layer 7 and the surface layer 8
Is in constant contact with the embossing projections formed on the roll, and the web of the base layer 7 and the web and roll of the surface layer 8 are constantly subjected to embossing pressure. In other words, the embossing pressure
Because it is not an intermittent form that does not work,
The continuous fibers 8a of the web of the surface layer 8 are easily spread on the base layer 7 with a uniform thickness, and the embossing machine is less likely to be damaged.

The laminated web of the web of the base layer 7 and the web of the surface layer 8 obtained by such a method is cut into an appropriate length after the joining line 15 shown in FIG. Is the cleaning sheet 1 of the illustrated example. Such a composite sheet is used as a cushioning material by increasing the bulk of the surface layer 8 as much as possible besides using it as the cleaning sheet 1, or by using a hydrophilic or water-absorbing fiber for the continuous fiber 8a of the surface layer 8. It can be used as a disposable or repeatedly used absorbent or the like for absorbing body fluid or other moisture.

[0025]

In the composite sheet according to the present invention, continuous fibers are bonded to the base layer with a uniform thickness, and the fiber distribution is not uneven. When this composite sheet is used as a cleaning sheet, it is easy to wipe the floor and the like uniformly.

The composite sheet of the present invention can be used for general household cleaning and other various products, and is practically useful.

[Brief description of the drawings]

FIG. 1 is a perspective view of a cleaning sheet.

FIG. 2 is a sectional view taken along line II-II of FIG.

FIG. 3 is a plan view of a cleaning sheet.

FIG. 4 is a view similar to FIG. 3, showing another example of the embodiment.

FIG. 5 is a drawing similar to FIG. 3, showing another example of the embodiment.

FIG. 6 is a drawing similar to FIG. 3, showing another example of the embodiment.

FIG. 7 is a partially enlarged view of FIG. 3;

FIG. 8 is a perspective view of a conventional cleaning sheet.

FIG. 9 is a perspective view of a conventional cleaning sheet.

FIG. 10 is a perspective view of a holder to which a cleaning sheet is attached.

[Explanation of symbols]

1 composite sheet (cleaning sheet) 5,5A, 5B, 5C, 5D , 5E, 5F joining line 7 base layer 8 surface 8a continuous fiber 8b ridge zone 8c side edge 9 side edges C-C axis _{H, H} 1, H ₂ imaginary line

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) // A61F 5/44 A61F 5/44 Z (72) Inventor Masaharu Tomioka Takasuka Wadahama, Toyohama-machi, Mitoyo-gun, Kagawa 1531-7 Unicharm Corporation Technical Center

Claims (18)

[Claims] 1. A composite sheet comprising a base layer having a longitudinal axis and having an upper surface and a lower surface, and a group of continuous fibers extending along the axis, between opposed side edges extending along the axis. A surface layer having a predetermined width defined and joining to at least one of the upper and lower surfaces by a plurality of joining lines extending in a direction intersecting with the axis, wherein the joining line is A plurality of first joining lines formed in one side area of the shaft by dividing the width into two equal parts, and a plurality of second joining lines formed in the other side area; The composite sheet, wherein a joining line and a second joining line obliquely intersect the continuous fiber group of the surface layer so as to intersect each other when extending toward the axis. 2. The method of claim 1, wherein the first and second joining lines extend substantially parallel to each other at substantially regular intervals on one side area and the other side area of the surface layer. Composite sheet. 3. The composite sheet according to claim 1, wherein the continuous fiber group in the surface layer is obtained by opening a continuous fiber tow and expanding the continuous fiber tow into a substantially uniform web having a predetermined width. 4. The composite sheet according to claim 1, wherein each of the first and second joining lines defines a compressed groove. 5. The surface layer has a raised area defining an arc between each pair of the first and second joining lines adjacent to each other,
Each of the raised areas has a higher bulkiness than the base layer,
The elasticity and compressibility, and the height of the raised area is formed to be at least three times as large as the total thickness of the first and second joint lines and the base layer. 4
The composite sheet according to any one of the above. 6. The length of the surface layer extending in the axial direction is in a range of 5 to 200 cm, and the width extending in a direction intersecting with the axial direction is in a range of 5 to 50 cm.
The composite sheet according to any one of claims 1 to 5, wherein 7. The base layer has a basis weight of 5 to 200 g / m.
² and the basis weight of the surface layer is 20 to 500 g / m.
The composite sheet according to any one of claims 1 to 6, which is in the range of ( ² ). 8. The composite sheet according to claim 1, wherein the continuous fiber group of the surface layer has a fineness per fiber of 1 to 20 d. 9. The composite sheet according to claim 1, wherein the first and second joining lines substantially intersect on the axis. 10. The composite sheet according to claim 1, wherein said first and second joining lines extend from said axis to an end of said surface layer. 11. A ratio of a maximum value to a minimum value of a sum of lengths of imaginary lines crossing the surface layer in a width direction orthogonal to the axis in a width direction and not exceeding 2 is equal to or less than 2. The composite sheet according to claim 1. 12. The base layer and the surface layer include a thermoplastic synthetic resin, and the first and second joining lines are formed by melting these synthetic resins.
12. The composite sheet according to any one of items 11 to 11. 13. The composite sheet according to claim 1, wherein said first and second joining lines are welding lines by pressurizing and heating. 14. A method of manufacturing a composite sheet having a longitudinal axis, the method comprising: a base layer web having an upper surface and a lower surface; and a group of continuous fibers extending along the axis. The composite sheet web is configured from a surface web having a predetermined width defined between opposed side edges extending along the surface web, and the surface web and the base layer web,
A plurality of joining lines that are continuously supplied in the axial direction, overlap the surface layer web on at least one surface of the base layer web, and extend the base layer web and the surface layer web in a direction intersecting the axis; And bonding the tow as a continuous fiber group of the surface layer web on at least one surface of the base layer web and expanding the tow to a required width. The web comprises a plurality of first joining lines formed on one side of the shaft by dividing the width into two equal parts, and a plurality of second joining lines formed on the other side of the shaft. The first joining line and the second joining line obliquely intersect with the continuous fiber group of the surface web so as to intersect each other when extending toward the axis, and the base layer web and the surface web are aligned in the axial direction. Supply to Occasionally, the manufacturing method characterized by comprising the first joining line and the each of the second joining line, are sequentially formed toward outside in the width direction of the surface layer web from said axis step. 15. The system according to claim 14, wherein the first and second joining lines extend substantially parallel to each other at substantially regular intervals on one side area and the other side area of the surface web. Manufacturing method. 16. Each of the first and second joining lines has a first end located closer to the axis and a second end located closer to the outside of the surface web. 1,
An imaginary line intersecting the first end of one of the two joining lines and crossing the surface web in the width direction is a second end of another joining line parallel to the one of the first and second joining lines. The manufacturing method according to claim 14 or 15, wherein the two cross each other. 17. A ratio of a maximum value to a minimum value of a sum of lengths in a width direction of a portion where an imaginary line crossing the surface web in the width direction intersects the first and second joining lines is 2 or less. 17. The method according to claim 14, wherein the first bonding line and the second bonding line are formed. 18. The method according to claim 14, wherein the first and second joining lines are formed by melting the base layer web and the surface layer web.