U.S. patent application number 10/507074 was filed with the patent office on 2005-07-14 for needle blade roll for quasi-cotton producing device.
This patent application is currently assigned to DAIKIN INDUSTRIES, LTD.. Invention is credited to Ohgami, Isao, Ohto, Tokumatsu, Yamamoto, Katsutoshi.
Application Number | 20050153820 10/507074 |
Document ID | / |
Family ID | 28035586 |
Filed Date | 2005-07-14 |
United States Patent
Application |
20050153820 |
Kind Code |
A1 |
Ohto, Tokumatsu ; et
al. |
July 14, 2005 |
Needle blade roll for quasi-cotton producing device
Abstract
A needle blade roll (12) for forming short fibers from a
material capable of formation of artificial cotton in an artificial
cotton fabricating apparatus is disclosed which is made up of a
roll main body (13) and a large number of needle blades (14)
implanted into a peripheral surface of the roll main body (13). In
the needle blade roll (12), each needle blade (14) is arranged at a
sloping angle relative to a radial line of the roll main body (13)
so that its leading end lies ahead of the radial line with respect
to the rotational direction of the roll main body (13). This makes
it possible to form short fibers the length of which is longer than
conventional, thereby fabricating artificial cotton made of such
short fibers which are fully intertwined with one another.
Inventors: |
Ohto, Tokumatsu; (Kanagawa,
JP) ; Yamamoto, Katsutoshi; (Osaka, JP) ;
Ohgami, Isao; (Osaka, JP) |
Correspondence
Address: |
NIXON PEABODY, LLP
401 9TH STREET, NW
SUITE 900
WASHINGTON
DC
20004-2128
US
|
Assignee: |
DAIKIN INDUSTRIES, LTD.
Umeda Center Bldg., 4-12, Nakazaki-nishi 2-chome,
Kita-ku
Osaka-shi, Osaka
JP
530-8323
|
Family ID: |
28035586 |
Appl. No.: |
10/507074 |
Filed: |
September 9, 2004 |
PCT Filed: |
March 19, 2003 |
PCT NO: |
PCT/JP03/03385 |
Current U.S.
Class: |
492/30 |
Current CPC
Class: |
D04H 1/732 20130101;
D01G 1/04 20130101; D01G 1/02 20130101; D01G 25/00 20130101; D01G
15/88 20130101; D04H 1/58 20130101; D04H 1/72 20130101 |
Class at
Publication: |
492/030 |
International
Class: |
D01D 001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 20, 2002 |
JP |
2002-078489 |
Claims
What is claimed is:
1. A needle blade roll for use in an artificial cotton fabricating
apparatus (1) which fabricates artificial cotton by forming from a
material (2) capable of formation of artificial cotton a large
number of short fibers (3) ranging in fiber length between 1 and
200 mm and by accumulating said short fibers (3), said needle blade
roll being mounted rotatably in a cylindrical casing (11) in order
that a large number of short fibers (3) can be formed from said
material (2), wherein said needle blade roll comprises a roll main
body (13) and a large number of needle blades (14) implanted into a
peripheral surface of said roll main body (13) and wherein each
said needle blade (14) is arranged at a sloping angle relative to
an associated radial line of said roll main body (13) so that its
leading end lies ahead of said radial line with respect to the
rotational direction of said roll main body (13).
2. The needle blade roll of claim 1, wherein said needle blades
(14) are implanted into said roll main body (13) so that said
sloping angle (0) relative to the radial line of said roll main
body (13) falls in a range of
5.degree..ltoreq..theta..ltoreq.30.degree..
3. The needle blade roll of either claim 1 or claim 2, wherein said
needle blades (14) are arranged in helical fashion on the
peripheral surface of said roll main body (13).
4. The needle blade roll of either claim 1 or claim 2, wherein the
clearance (C) between said leading ends of said needle blades (14)
of said roll main body (13) and an internal peripheral surface of
said casing (11) falls in a range of 50 .mu.m.ltoreq.C.ltoreq.500
.mu.m.
5. The needle blade roll of claim 1, wherein said material (2)
capable of formation of artificial cotton of said artificial cotton
fabricating apparatus (1) is composed of at least one selected from
the group consisting of synthetic resin, yarn, and sliver.
6. The needle blade roll of claim 1, wherein said material (2)
capable of formation of artificial cotton of said artificial cotton
fabricating apparatus (1) is a synthetic resin.
7. The needle blade roll of either claim 5 or claim 6, wherein said
synthetic resin comprises a fluoropolymer.
8. The needle blade roll of claim 7, wherein said fluoropolymer
comprises polytetrafluoroethylene and/or an
ethylene/tetrafluoroethylene copolymer.
9. The needle blade roll of claim 8, said polytetrafluoroethylene
and/or ethylene/tetrafluoroethylene copolymer comprises a uniaxial
drawn substance.
10. The needle blade roll of claim 5, wherein said yarn comprises
glass fibers or carbon fibers.
11. The needle blade roll of claim 5, wherein said sliver comprises
aramid fibers, polyimide fibers, sheep wool, or natural fibers.
Description
TECHNICAL FIELD
[0001] The present invention relates to a needle blade roll for
forming a large number of short fibers from a material capable of
formation of a cotton-like substance (hereinafter artificial
cotton) in an artificial cotton fabricating apparatus which
fabricates artificial cotton by accumulation of such short
fibers.
BACKGROUND ART
[0002] In this type of conventional artificial cotton fabricating
apparatus such as the one shown in FIG. 11, many (numerous) short
fibers (102) ranging in fiber length between 1 to 200 mm are formed
from a fiber material (101) in the form of a yarn, a sliver et
cetera. These short fibers (102) are accumulated on an accumulation
surface member (e.g., a mesh belt (103), a base paper sheet et
cetera) while causing the mesh belt (103)) to travel, and
artificial cotton is fabricated successively (see for example
Japanese Patent Kokai Publication No. 1997-193277). The fiber
material (101) may be any type of material that is capable of
formation of artificial cotton. As the fiber material (101),
various materials including synthetic resin have been used.
[0003] The artificial cotton fabricating apparatus (100) of this
conventional type usually employs, as a means for forming short
fibers (102) from the fiber material (101), a needle blade roll
(106) comprising a roll main body (104) and a large number of
needle blades (105) implanted into the outer peripheral surface of
the roll main body (104). The needle blade roll (106) is mounted in
the inside of a cylindrical casing (107) having a supply inlet for
the fiber material (101) and a discharge outlet for the short
fibers (102), these openings being formed in a spaced apart
relationship with each other in the circumferential direction. The
discharge outlet of the casing (107) opens to a wind channel (108)
which is air-sucked from below. In addition, the mesh belt (103)
and its forwarding mechanism (not shown) are arranged under the
wind channel (108).
[0004] In order to form a large number of short fibers (102), in
the apparatus (100) the fiber material (101) is fed through a very
narrow clearance between the needle blade roll (106) and the casing
(107) and, at the same time, the needle blade roll (106) is rotated
at high speed. The short fibers (102) thus formed are dispersed in
the wind channel (108). And, the short fibers (102) dispersed in
the wind channel (108) are intertwined with one another and are
accumulated on the conveyor belt (103). As a result, artificial
cotton is fabricated.
PROBLEMS TO BE SOLVED
[0005] And now, in the conventional needle blade roll (106), each
of the blade needles (105) is arranged on the circumferential
surface of the roll main body (104) along the direction of a
respective radial line thereof. Alternatively, each of the blade
needles (105) is arranged at a sloping angle with respect to a
respective radial-line direction so that its leading end is
situated behind relative to the rotational direction of the needle
blade roll (106). Stated another way, the needle blades (105) are
arrayed at right angles to the circumferential surface of the roll
main body (104) or inclined backward.
[0006] However, in the case where such a conventional needle blade
roll (106) is employed, the length of short fibers (102) formed
from the fiber material (101) tends to become too short.
Consequently, when a large number of short fibers (102) are
accumulated on the upper surface of the mesh belt (103) or the
like, there is the possibility that it becomes difficult for the
short fibers (102) to twine together. The reason for the short
fibers (102) formed by the aforesaid construction to result in
having too short a fiber length is explainable as follows. It is
possible to form short fibers (102) having a longer length if the
fiber material (101) is finely segmentalized while causing the
needle blades (105) to "bite" firmly into the material (101);
however, if such a "biting" action is insufficient, the cutting
action of the needle blades (105) on the fiber material (101)
within the casing (107) increases.
[0007] Bearing in mind these problems, the present invention was
made. Accordingly, an object of the present invention is to make it
possible to fabricate artificial cotton from short fibers which are
intertwined sufficiently by providing an improved needle blade roll
capable of forming short fibers which are longer in length than
conventional.
DISCLOSURE OF INVENTION
[0008] The present invention is characterized in that each of
needle blades (14) of a needle blade roll is inclined against the
circumferential surface of a roll main body (13) so as to lie ahead
with respect to the rotational direction of the roll main body
(13).
[0009] More specifically, an invention as set forth in claim 1 is
directed to a needle blade roll for use in an artificial cotton
fabricating apparatus (1) which fabricates artificial cotton by
forming from a material (2) capable of formation of artificial
cotton a large number of short fibers (3) ranging in fiber length
between 1 and 200 mm and by accumulating the short fibers (3),
wherein the needle blade roll is mounted rotatably in a cylindrical
casing (11) in order that a large number of short fibers (3) can be
formed from the material (2).
[0010] And, the needle blade roll is characterized in that it is
made up of a roll main body (13) and a large number of needle
blades (14) implanted into a peripheral surface of the roll main
body (13) and that each needle blade (14) is arranged at a sloping
angle relative to an associated radial line of the roll main body
(13) so that its leading end lies ahead of the radial line with
respect to the rotational direction of the roll main body (13).
[0011] In the invention as set forth in claim 1, when the material
(2) is fed through a clearance between the needle blade roll and
the casing (11), a large number of short fibers (3) are formed
because the needle blade roll is rotated at high speed. In
addition, the short fibers (3) are dispersed in a wind channel and
then are accumulated on a conveyor belt or the like while they are
intertwined with one another, whereby artificial cotton is
fabricated.
[0012] And, since each needle blade (14) is inclined relative to an
associated radial line of the roll main body (13) so that its
leading end lies ahead of the radial line with respect to the
rotational direction of the roll main body (13), this
satisfactorily prolongs the length of time of the "biting" of the
needle blades (14) into the material (2), thereby weakening the
action of cutting of the needle blades (14) on the material (2). As
a result, short fibers (3) formed from the material (2) have no
longer a tendency to have too short a fiber length. Because of
this, the short fibers (3) are formed, having a longer length
dimension than conventional. Accordingly, when fabricating
artificial cotton by accumulation of a large number of such short
fibers (3), the action of causing the short fibers (3) to be
intertwined with one another is produced.
[0013] In addition, an invention as set forth in claim 2 according
to the needle blade roll of claim 1 is characterized in that the
needle blades (14) are implanted into the roll main body (13) so
that the sloping angle (0) relative to the radial line of the roll
main body (13) falls in a range of
5.degree.<.theta.<30.degree..
[0014] If the sloping angle .theta. of each needle blade (14) to
the radius of the roll main body (13) is not more than five
degrees, then the action of cutting of the needle blades (14) on
the material (2) increases and therefore the length of the short
fibers (3) often results in becoming shorter. In the invention as
set forth in claim 2, however, the cutting action is weakened. If
the sloping angle .theta. exceeds thirty degrees, then the needle
blade roll is likely to rotate at idle. In the invention as set
forth in claim 2, however, such idling will not take place.
[0015] In addition, an invention as set forth in claim 3 according
to the needle blade roll of either claim 1 or claim 2 is
characterized in that the needle blades (14) are arranged in
helical fashion on the peripheral surface of the roll main body
(13).
[0016] In the invention as set forth in claim 3, because of the
arrangement that the needle blades (14) are arranged helically, the
phase of each of the needle blades (14) deviates with respect to
the direction in which the material (2) is fed, as a result of
which the action of finely cutting the material (2) into a large
number of short fibers (3) occurs uniformly all over the needle
blade roll.
[0017] In addition, an invention as set forth in claim 4 according
to the needle blade roll of either claim 1 or claim 2 is
characterized in that the clearance (C) between the leading ends of
the needle blades (14) of the roll main body (13) and an internal
peripheral surface of the casing (11) falls in a range of 50
.mu.m.ltoreq.C.ltoreq.500 .mu.m.
[0018] If the clearance C falls below the lower limit of the above
range, then there is the possibility that the needle blade roll
(12) is brought to a stop by fiber jam. In the invention as set
forth in claim 4, however, the aforesaid possibility is low. On the
other hand, if the clearance C exceeds the upper limit of the above
range, then the needle blade roll (12) is likely to rotate at idle.
In the invention as set forth in claim 4, however, such idling will
not take place.
[0019] Furthermore, inventions as set forth in claims 5-11 are
characterized in that the material (2) is specified.
[0020] More specifically, an invention as set forth in claim 5
according to the invention of claim 1 is characterized in that the
material (2) capable of formation of artificial cotton of the
artificial cotton fabricating apparatus (1) is composed of at least
one selected from the group consisting of synthetic resin, yarn,
and sliver. In other words, the material (2) is composed of one of
these materials or a combination of two or more of them.
[0021] In addition, an invention as set forth in claim 6 according
to the invention of claim 1 is characterized in that the material
(2) capable of formation of artificial cotton of the artificial
cotton fabricating apparatus (1) is a synthetic resin.
[0022] In addition, an invention as set forth in claim 7 according
to the invention of either claim 5 or claim 6 is characterized in
that the synthetic resin comprises a fluoropolymer.
[0023] In addition, an invention as set forth in claim 8 according
to the invention of claim 7 is characterized in that the
fluoropolymer comprises polytetrafluoroethylene and/or an
ethylene/tetrafluoroethylene copolymer.
[0024] In addition, an invention as set forth in claim 9 according
to the invention of claim 8 is characterized in that the
polytetrafluoroethylene and/or ethylene/tetrafluoroethylene
copolymer comprises a uniaxial drawn substance.
[0025] In addition, an invention as set forth in claim 10 according
to the invention of claim 5 is characterized in that the yarn
comprises glass fibers or carbon fibers.
[0026] Finally, an invention as set forth in claim 11 according to
the invention of claim 5 is characterized in that the sliver
comprise aramid fibers, polyimide fibers, sheep wool, or various
natural fibers.
EFFECTS
[0027] In accordance with the invention as set forth in claim 1,
each needle blade (14) of the needle blade roll is, on the
circumferential surface of the roll main body (13), inclined
against the radial line of the roll main body (13) so as to lie
ahead relative to the rotational direction of the roll main body
(13). As a result of such arrangement, at the time when the
material (2) capable of formation of artificial cotton is fed
through the clearance C between the needle blade roll and the
casing (11), the "biting" of the needle blades (14) into the
material (2) becomes sufficient, thereby forming short fibers (3)
having a longer length than conventional. Accordingly, in the case
where artificial cotton is fabricated by accumulation of a great
number of short fibers (3), the short fibers (3) are fully
intertwined with one another, thereby making it possible to enhance
the strength of the artificial cotton.
[0028] In addition, in accordance with the invention as set forth
in claim 2, the needle blades (14) are inclinedly implanted into
the roll main body (13) so that the sloping angle 0 of each needle
blade (14) with respect to the radius of the needle blade roll
falls in a range of 5.degree..ltoreq..theta..ltoreq.30.degree.. If
the sloping angle .theta. is less than five degrees, the "biting"
of the needle blades (14) into the material (2) is weakened and the
length of fibers often results in becoming shorter, and if the
sloping angle .theta. exceeds thirty degrees, the needle blade roll
is likely to rotate at idle. The invention as set forth in clam 2
eliminates these drawbacks.
[0029] In addition, in accordance with the invention as set forth
in claim 3, the needle blades (14) are arranged helically. As a
result of such arrangement, the phase of each of the needle blades
(14) deviates with respect to the direction in which the material
(2) is fed, thereby making it possible to equalize segmentalization
that each needle blade (14) performs on the material (2).
[0030] Finally, in accordance with the invention as set forth in
claim 4, it is arranged such that the clearance C between the
leading end of each of the needle blades (14) of the roll main body
(13) and the internal peripheral surface of the casing (11) falls
in a range of 50 .mu.m.ltoreq.C.ltoreq.500. If the clearance C
falls below the lower limit of the range, then there is the
possibility that the needle blade roll (12) is brought to a stop by
fiber jam. In the invention as set forth in claim 4, however, the
aforesaid possibility is low. If the clearance C exceeds the upper
limit of the range, then the needle blade roll (12) is likely to
rotate at idle. In the invention as set forth in claim 4, however,
such idling will not take place.
BRIEF DESCRIPTION OF DRAWINGS
[0031] FIG. 1 is a perspective illustration showing a general
arrangement of an artificial cotton fabricating apparatus according
to a first embodiment of the present invention;
[0032] FIG. 2 is an axial cross-sectional view of a roll unit;
[0033] FIG. 3 is an axial perpendicular cross-sectional view of the
roll unit;
[0034] FIG. 4 is a partially enlarged cross-sectional view of a
needle blade roll;
[0035] FIG. 5 is an outline view of the needle blade roll;
[0036] FIG. 6 is an enlarged cross-sectional view of a wind channel
and component parts on the periphery thereof;
[0037] FIG. 7 is a cross-sectional view taken along line VII-VII of
FIG. 6;
[0038] FIG. 8 is a diagram depicting the flow of air in an upper
portion of the wind channel;
[0039] FIG. 9 is an enlarged view of a wind channel and its
neighboring component parts in a first modification example of the
first embodiment;
[0040] FIG. 10 is a diagram depicting the flow of air in an upper
portion of a wind channel in a second modification example of the
first embodiment; and
[0041] FIG. 11 is a schematic diagram showing an arrangement of a
conventional artificial cotton fabricating apparatus.
BEST MODE FOR CARRYING OUT INVENTION
[0042] Hereinbelow, an embodiment of the present invention will be
described in detail with reference to the drawings.
[0043] General Structure
[0044] FIG. 1 is a perspective view showing a general arrangement
of an artificial cotton fabricating apparatus (1). In the apparatus
(1), many (numerous) short fibers (3) are formed from a material
(2) (hereinafter referred to as a "fiber material") capable of
formation of artificial cotton. While the short fibers (3) are
accumulated on a paper base material (a base paper sheet (20)), the
base paper sheet (20) is moved in its plane direction. In this way,
artificial cotton is fabricated in succession.
[0045] The artificial cotton fabricating apparatus (1) is made up
of a roll unit (10) for forming a large number of short fibers (3)
from the fiber material (2), a base paper sheet (20) serving as an
accumulation surface member for accumulating the short fibers (3)
under the roll unit (10), a wind channel (30) which communicates
from the roll unit (10) onto the base paper sheet (20) and which is
air-sucked from below the base paper sheet (20), and a forwarding
mechanism (40) for continuously forwarding the base paper sheet
(20) in its plane direction. In addition to these component parts,
the artificial cotton fabricating apparatus (1) further includes
other component parts, i.e., a material supplying mechanism (50)
for supplying the roll unit (10) with the fiber material (2), an
air discharge mechanism (60) for performing suction of air from the
wind channel (30) by forced air discharge under the base paper
sheet (20), and a take-up mechanism (70) for artificial cotton
fabricated.
[0046] Material Supplying Mechanism
[0047] The material supplying mechanism (50) supplies the fiber
material (2) in the form of a yarn or sliver to the roll unit (10).
The material supplying mechanism (50) has a plurality of bobbins
(51) on which respective fiber materials (2) are wound, guide rolls
(52, 53) for guiding the plurality of the fiber materials (2) to
the roll unit (10), and nip rolls (54, 55) which are arranged
vertically so that the fiber materials (2) are compressed tightly
therebetween. The nip rolls (54, 55) are brought into pressure
contact with each other. When the nip rolls (54, 55) are
rotationally driven, they perform an operation of pushing the fiber
materials (2) into the roll unit (10).
[0048] Fiber Material
[0049] At least one of synthetic resin, yarn, and sliver can be
selected for use as the fiber material (2). Of these materials,
fluoropolymer can be employed as the synthetic resin. As the
fluoropolymer, polytetrafluoroethylene (PTFE) and/or
ethylene/tetrafluoroethylene copolymer (ETFE) can be employed. PTFE
and/or ETFE can be formed of a uniaxial drawn substance. The film
thickness of the fiber material (2) is about 30 .mu.m.
[0050] The fiber material (2) may be formed entirely of PTFE
fibers. Alternatively, it may be arranged such that some of the
fiber materials (2) are PTFE fibers and the remaining is a
different type of fiber. In other words, PTFE-fiber bobbins (51)
and bobbins (51) for a different type of fiber may be employed
mixedly. In addition, instead of using PTFE fibers, it is possible
to employ ethylene/tetrafluoroethylene copolymer (ETFE) fibers. In
such a case, all the fiber materials may be ETFE fibers.
Alternatively, it may be arranged such that some of the fiber
materials (2) are ETFE fibers and the remaining is a different type
of fiber.
[0051] As the different type of fiber, a yarn formed of glass or
carbon fibers or a sliver formed of aramid fibers, polyimide
fibers, sheep wool, or various natural fibers may be available. The
reason for employing a sliver of natural fibers is explained as
follows. For the case of cotton (or wool), its single fiber has a
length of less than 10 cm at longest and, in order to make it
possible to deal with this continuously, fibers are dealt with as a
bundle (sliver) of fibers slightly twisted while arranging the
fibers in the same direction. In addition, the reason for employing
a sliver of aramid or polyimide fibers is explained as follows.
Aramid and polyimide fibers are those that have a higher strength
in comparison with other synthetic resins, so that it is preferable
that they are precut into short fibers of about 50 mm and are dealt
with after being reshaped into a sliver for the reduction in load
on the needle blades and for the achievement of uniform stirring.
On the other hand, industrial fibers such as glass fiber, carbon
fiber et cetera are supplied to the apparatus in the form of a
continuous yarn.
[0052] The aforesaid different type of fiber will be described in
further detail, including the above-described example. Any one of
inorganic fiber, heat-resisting synthetic fiber, polyolefin fiber,
polyester fiber, and natural fiber or a combination of two or more
of them may be employed.
[0053] As the inorganic fiber, for example carbon fiber, glass
fiber, metallic fiber, asbestos, rock wool et cetera may be
employed. In addition, as the metallic fiber, for example stainless
steel fiber, copper fiber, steel fiber et cetera may be
employed.
[0054] Furthermore, as the heat-resisting synthetic fiber, for
example polyphenylene sulfide (PPS) fiber, polyimide (PI) fiber,
aramid fiber (para-aramid fiber, meta-aramid fiber), phenol fiber,
polyarylate fiber, carbide fiber, fluorine-containing resin fiber
et cetera may be employed. As the fluorine-containing resin fiber,
for example tetrafluoroethylene-perfluoro (alkyl vinyl ether)
copolymer (PFA) fiber, tetrafluoroethylene-hexafluoro propylene
copolymer (FEP) fiber, polyvinyl fluoride (PVF) fiber,
polyvinylidene fluoride (PVdF) fiber, polychlorotrifluoroethylene
(PCTFE) fiber, ethylene-chlorotrifluoroethyle- ne copolymer (ECTFE)
fiber et cetera may be employed.
[0055] In addition, as the polyolefin fiber, for example
polyethylene fiber, polypropylene fiber, nylon fiber, urethane
fiber et cetera may be employed. Additionally, as the polyester
fiber, for example polyethylene terephthalate fiber, polybutylene
terephthalate fiber et cetera may be employed. Finally, as the
natural fiber, for example wool, cotton, cashmere, angora, silk,
linen, pulp et cetera may be employed.
[0056] Roll Unit
[0057] The roll unit (10), as shown in FIG. 2 which is an axial
cross-sectional view and in FIG. 3 which is an axial perpendicular
cross-sectional view, is made up of a cylindrical casing (11) and a
needle blade roll (12) as a roll member for formation of short
fibers (3) which is housed in the inside of the casing (11). The
casing (11) is provided with a supply inlet (11a) for the fiber
material (2) and a discharge outlet (11b) for the short fibers (3),
these openings being formed in a spaced apart relationship with
each other in the circumferential direction. On the other hand, the
needle blade roll (12) is provided with a roll main body (13) and a
large number of needle blades (14) implanted into the peripheral
surface of the roll main body (13). The needle blade roll (12) is
dimension-constructed so that a fine clearance is formed between
the leading end of each needle blade (14) and the inner peripheral
surface of the casing (11). And, the roll unit (10) breaks the
fiber material (2) supplied from the supply inlet (11a) into a
large number of short fibers (3) by rotation of the needle blade
roll (12) and discharges them through the discharge outlet (11b).
Representation of the needle blades (14) is omitted in FIG. 2. FIG.
3 shows only some of the needle blades (14).
[0058] The casing (11) has an upper casing (11c) and a lower casing
(11d). The upper and lower casings (11c) and (11d) constitute an
upper and a lower portion of a single cylindrical tube,
respectively. In addition, in FIG. 3 the supply inlet (11a) is
formed in a left side portion of the cylindrical tube while the
discharge outlet (11b) is formed in a right-side portion
thereof.
[0059] The roll main body (13) of the needle blade roll (12) is
made up of an external cylinder (13a), an internal cylinder (13b),
a shaft (13c) which is the central axis of rotation of the external
and internal cylinders, and a circular plate (13d) connecting the
external cylinder (13a), the internal cylinder (13b), and the shaft
(13c), wherein these components are united together into a single
unit, i.e., the roll main body (13).
[0060] Bearing plates (11e) and (11f) are mounted at both ends of
the upper and lower casings (11c) and (11d). Ball bearings (15, 15)
are mounted on associated bearing plates (11e, 11f) so that the
ball bearings (15, 15) engage the shaft (13c) and rotatably support
the needle blade roll (12). The bearing plates (11e, 11f) are
provided with respective retainer (16a, 16b) for preventing the
slipping-off of the ball bearings (15, 15). In addition, a bearing
nut (17) is mounted onto the shaft (13c) on the assembly side of
the roll unit (10) (the left-hand side in the figure). A pulley
(18) is mounted at one end of the shaft (13c) and the needle blade
roll (12) is rotated when the belt is driven.
[0061] As shown in detail in FIG. 4, the needle blades (14) of the
needle blade roll (12) are implanted into the external cylinder
(13a) of the roll main body (13). Each needle blade (14) is
inclined forward relative to a radial line of the roll main body
(13) so that its leading end lies behind the radial line with
respect to the rotational direction of the roll main body (13).
More specifically, the angle of sloping of each needle blade (14)
with respect to an associated radial line of the roll main body
(13), .theta., falls in a range of 5.degree..ltoreq..theta..lto-
req.30.degree.. More preferably it is set such that
.theta.=20.degree.. The lower limit of the angle range is
determined for the reason that if the sloping angle (.theta.) is
less than it this makes it difficult for the needle blades (14) to
"bite" firmly into the fiber material. On the other hand, the upper
limit is determined for the reason that if the sloping angle
(.theta.) exceeds it the needle blade roll (12) tends to rotate at
idle in the casing (11).
[0062] Furthermore, the needle blades (14) are arranged equally in
the circumferential direction of the roll main body (13) at such a
pitch that the central angle (.alpha.) is 4.degree.. In other
words, the needle blades (14) are disposed at positions as a result
of dividing the circumference of the roll main body (13) into 90
equal parts. Furthermore, as shown in FIG. 5, the needle blades
(14) are arranged continuously in helical fashion at a given very
small torsional angle (.beta.) on the peripheral surface of the
roll main body (13).
[0063] The internal cylinder (13b) is formed by an iron tube. In
addition, the needle blades (14) are made of steel material.
Furthermore, the external cylinder (13a) is formed by a brass tube
because of its workability for the implanting of the needle blades
(14) and resistant to rust.
[0064] For example, the needle blades (14) are those shaped like a
thin circular cone as a whole (see FIG. 4) having a base diameter
of 0.9 mm and an overall length of 9 mm. Alternatively, the needle
blades (14) are those shaped, as a whole, like a cylinder with a
pointed part on the top (not shown). The needle blade roll (12) is
formed such that it has a diameter of 100 mm (at the leading ends
of the needle blades (14)) and an axial length of 200 mm. In
addition, the outer diameter of the external cylinder (13a) is for
example 93 mm and the amount of projection of the needle blades
(14) in the radial direction of the needle blade roll (12) is set
to 3.5 mm.
[0065] And, with respect to the needle blade roll (12) thus
dimension-constructed, the casing (11) is constructed as follows.
That is, 50 .mu.m.ltoreq.C.ltoreq.500 .mu.m (more preferably C=200
.mu.m) where C is the clearance defined between the inner
peripheral surface of the casing (11) and the leading end of each
needle blade (14) (see FIG. 4). The lower limit of the range is
determined in view of the possibility that the needle blade roll
(12) is stopped by fiber jam if the clearance C is less than the
lower limit. On the other hand, the upper limit of the range is
determined in view of the fact that the needle blade roll (12) is
likely to rotate at idle if the clearance C exceeds the upper
limit.
[0066] In the above-described configuration, L/R=3.5/46.5=0.075
where the radius of the external cylinder (13a) is R and the
projection amount of the needle blades (14) is L; however, it may
be arranged such that the projection amount L is varied within a
range of from 2.0 to 5.0 so that L/R falls in a range of
2.0/46.5.ltoreq.L/R.ltoreq.5.0/46.5. The reason for this is
explained as follows. If L/R is less than the lower limit of the
range, then the needle blade roll (12) tends to rotate at idle in
the casing (11). On the other hand, if L/R exceeds the upper limit
of the range, then there is the possibility that the needle blade
(14) is broken.
[0067] The needle blade roll (12) is so constructed as to rotate at
a rotational speed of from 5000 to 10000 min.sup.-1. And, when the
needle blade roll (12) dimension-constructed as above rotates in
the casing (11) at such a high speed, a large number of short
fibers (3) (fiber diameter: about 12 .mu.m; length: about 16 mm, on
the average) are formed from the fiber material (2).
[0068] The foregoing dimension configurations and so on are shown
only by way of example. Therefore, adequate modifications thereon
is possible depending on the apparatus configuration. In addition,
although in some cases the short fibers (3) are formed having
different fiber lengths according to the fiber diameter and the
material, it suffices if the fiber length falls roughly within a
range of from 1 to 200 mm.
[0069] Accumulation Surface Member, Forwarding Mechanism, and
Take-Up Mechanism
[0070] In the present embodiment, the base paper sheet (20) serves
as an accumulation surface member by which short fibers (3)
discharged from the discharge outlet (11b) of the casing (11) are
accumulated below the roll unit (10). The base paper sheet (20),
made of a paper base material having the property of being
permeable to air, is fed to the apparatus (1) from a base paper
roll (21) and is collected, after completion of the fabrication of
artificial cotton on the surface thereof, by a take-up roll (70) as
a take-up mechanism.
[0071] In the present embodiment, the take-up roll (70) and the
base paper roll (21) serve as a driving roll and as a driven roll,
respectively. In addition, between the base paper roll (21) and the
take-up roll (70), a plurality of nip rolls (41) are provided on
the upper side while a traveling guide conveyor (43) formed by an
endless mesh belt (42) is provided on the lower side. By such
arrangement, the forwarding mechanism (40), by which the base paper
sheet (20) is guided while being moved, is constructed.
[0072] The five nip rolls (41) shown in the figure are arranged
such that they are brought into press contact with each other.
These nip rolls (41) are configured such that the base paper sheet
(20) on which a large number of short fibers (3) are accumulated
passes sequentially between vertically neighboring nip rolls (41)
from below while being turned over sequentially along the surfaces
of the lower four nip rolls (41). Having passed through between the
last two nip rolls (41), the base paper sheet (20) is collected by
the take-up roll (70) by way of a guide roll (45).
[0073] The traveling guide conveyor (43) is constructed so that the
endless mesh belt (42) is made to continuously go around in orbit
by five rollers (44). For example, these five rollers (44) are a
driving roller, three driven rollers, and a roller with a tension.
The traveling guide conveyor (43) is configured so that the endless
mesh belt (42) travels at the same speed as the base paper sheet
(20) while the base paper sheet (20) is guided.
[0074] Wind Channel and Air Discharge Mechanism
[0075] FIG. 6 is an enlarged cross-sectional view of the wind
channel (30) and its peripheral portions. FIG. 7 is a
cross-sectional view taken along line VII-VII of FIG. 6. In FIG. 6,
the traveling guide conveyor (43) is represented in a simplified
manner.
[0076] The wind channel (30) and the air discharge mechanism (60)
are arranged vertically, facing each other across the base paper
sheet (20) and the endless mesh belt (42). The wind channel (30)
and the air discharge mechanism (60) substantially communicate with
each other. The wind channel (30) is shaped like substantially a
rectangle in cross section defined by a front plate (30a) situated
on the side at which the base paper sheet (20) is fed, a rear plate
(30b) situated opposite to the front plate (30a), and side plates
(30c, 30d) in junction with ends of the front and rear plates (30a)
and (30b); note that in FIG. 1 representation of the side plate
(30d) on the near side is omitted. In addition, the air discharge
mechanism (60) is provided, at its upper end, with a duct (61)
shaped like an opening which faces a lower end of the wind channel
(30). The air discharge mechanism (60) sucks air from the wind
channel (30) by forced air discharge by an air discharge fan (not
shown) and creates a downward current of air in the wind channel
(30).
[0077] At the lower end of the wind channel (30), rollers (31a,
31b) which rotate while abutting on the base paper sheet (20) are
provided on the front plate's (30a) side and on the rear plate's
(30b) side, respectively. The roller (31a) on the side of the front
plate (30a) has a function of preventing outside air from entering
the wind channel (30). On the other hand, the roller (31b) on the
side of the rear plate (30b) has, in addition to a function of
preventing the entrance of outside air, another function of holding
down the short fibers (3) accumulated on the base paper sheet (20).
Furthermore, a rectification lattice (62) is provided at the
opening portion of the upper end of the duct (61) of the air
discharge mechanism (60).
[0078] The roll unit (10) is fixed to the upper end of the front
plate (30a) of the wind channel (30), and the discharge outlet
(11b) of the roll unit (10) opens to the inside of the wind channel
(30). The rear plate (30b) of the wind channel (30) is composed of
a plate material thinner but longer in height than the front plate
(30a). A portion of the rear plate (30b) extending from its lower
end to a point thereof at a slightly lower level than the upper end
of the front plate (30a) runs parallel with the front plate (30a)
and a portion of the rear plate (30b) above the parallel portion is
bent in such a direction that it is spaced away from the front
plate (30a).
[0079] The wind channel (30) is provided with a short fiber
stirring plate (32) for achieving uniform dispersion of a large
number of short fibers (3) discharged from the roll unit (10) in
the wind channel (30). The short fiber stirring plate (32) is a
member having a width dimension corresponding to the internal
dimension of the lateral side plates (30c, 30d) and its both ends
are fixed to the side plates (30c, 30d).
[0080] In addition, the short fiber stirring plate (32) is so
formed as to have, in cross section, the shape of a flat T defined
by a base plate portion (33) and a vortex flow creating plate (34)
fixed to an underside of the base plate portion (33). The short
fiber stirring plate (32) is arranged diagonally in the inside of
the wind channel (30), and the vortex flow creating plate (34) is
situated midway between an upper end (33b) and a lower end (33a) of
the base plate portion (33). Furthermore, in the short fiber
stirring plate (32), the lower end (33a) of the base plate portion
(33) is in close proximity to the rear plate (30b) of the wind
channel (30), the upper end (33b) is situated above the roll unit
(10), and a leading end (34a) of the vortex flow creating plate
(34) is in close proximity to the upper casing (11c) of the roll
unit (10). In this arrangement, the leading end (34a) of the vortex
flow creating plate (34) is situated at a higher level than the
lower end (33a) of the base plate portion (33).
[0081] A main flow path on the rear plate's (30b) side and a sub
flow path on the front plate's (30a) side are divisionally formed
by the short fiber stirring plate in the inside of the wind channel
(30).
[0082] Running Operation
[0083] Hereinbelow, the running operation of the artificial cotton
fabricating apparatus (1) will be described.
[0084] In the first place, in the material supplying mechanism
(50), a plurality of fiber materials (2) containing PTFE and ETFE
fibers or these fibers together with other fibers are supplied from
each bobbin (51) to the roll unit (10) via the guide rolls (52, 53)
and the nip rolls (54, 55). Each fiber material (2) is pushed into
the casing (11) from the supply inlet (11a) of the casing (11) and
flows between the lower casing (11d) and the needle blade roll (12)
in the direction of the discharge outlet (11b).
[0085] Although the film thickness of the fiber material (2) of
PTFE and ETFE (about 30 .mu.m) is sufficiently smaller than the
clearance C (from 50 to 500 .mu.m) between the casing (11) and the
needle blade roll (12) and is also sufficiently smaller than the
space between adjacent needle blades (14), the fiber material (2)
is cut into short fibers (3) having a fiber diameter of about 12
.mu.m and an average length of about 16 mm by the needle blades
(14), because the needle blade roll (12) rotates at high speed. At
that time, since the nip rolls (54, 55) rotate at low speed while
the needle blade roll (12) rotates at high speed, the fiber
material (2) is cut while being stretched and is strongly stirred
in the clearance C, the short fibers (3) after cutting become
slightly wrinkled.
[0086] The short fibers (3) are blown into the wind channel (30).
In the inside of the wind channel (30), a downward current of air
is created by forced air discharge in the air discharge mechanism
(60) and the short fibers (3) ride this air current, are dispersed
in the inside of the wind channel (30), and are accumulated on the
surface of the base paper sheet (20).
[0087] Here, air sucked from above the wind channel (30) will pass
through flow-restrictions in the main and sub flow paths. With
respect to the short fiber stirring plate (32), the main flow path
is a flow path on the rear plate's (30b) side while the sub flow
path is a flow path on the front plate's (30a) side (the roll
unit's (10) side). In addition, since air sucked from above the
wind channel (30) always passes through the two flow-restrictions,
this causes the downstream negative pressure to become greater than
conventional, thereby creating relatively strong jet flows at the
outlets of the flow-restrictions. And, the short fibers (3) are
stirred uniformly in the wind channel (30) by the mutual action of
the jet flows generated in the two areas. The generation of such
strong jet flows also has to do with the increase in ventilation
resistance between the vortex flow creating plate (34) and the roll
unit (10) due to the bending of the flow of air caused by the
vortex flow creating plate (34) being intersecting with an air flow
in the sub flow path.
[0088] In addition, a vortex flow is created downstream of the
flow-restriction on the side of the sub flow path by the action of
blow-off air generated by the needle blade roll (12) rotating at
high speed and a jet flow from the flow-restriction (see FIG. 8
which indicates the flow of air). The vortex flow circulates and
moves along the base plate portion (33) from below the vortex flow
creating plate (34) and finally flows together with an air flow
from the sub flow path. Accordingly, since air does not linger at
the underside of the vortex flow creating plate (34) and the base
plate portion (33), the short fibers (3) does not linger either.
Therefore, problems such as adhesion will not arise. Besides, the
short fibers (3) are dispersed more uniformly within the wind
channel (3) by the effect of being stirred by a vortex flow.
[0089] In addition, although there is created an upward current of
blow-off air in the discharge outlet (11b) of the roll unit (10),
the short fibers (3) are not blown out of the apparatus by the
upward current because of a strong jet flow generated from the
flow-restriction of the sub flow path.
[0090] The large number of the short fibers (3) thus dispersed
within the wind channel (30) ride a current of air and are
conveyed. When the short fibers (3) reach the surface of the base
paper sheet (20), they are intertwined with one another while
receiving the action of sucking forces from the air discharge
mechanism (60) and are accumulated there. And, during the time that
the base paper sheet (20) travels to the take-up roll (70) from the
base paper roll (21), the short fibers (3) accumulated on the
surface of the base paper sheet (20) are compression bonded
together by the nip rolls (41) to form artificial cotton.
Alternatively, the short fibers (3) may be thermo
compression-bonded together by the nip rolls (41). Before use, the
base paper sheet (20) is detached from the artificial cotton
fabricated.
Effects of Embodiment
[0091] In the present embodiment, the lower end (33a) of the base
plate portion (33) of the short fiber stirring plate (32) is
arranged close to the rear plate (30b) of the wind channel (30) and
the leading end (34a) of the vortex flow creating plate (34) lies
close to the roll unit (10). As a result of such arrangement, a
current of air flows through the two flow-restrictions while the
air current is bend in a curve on the sub flow path side, thereby
increasing negative pressure in the inside of the wind channel (30)
thereby to create strong jet flows at the outlets of the
flow-restrictions of the main and sub flow paths. Consequently, the
short fibers (3) are stirred uniformly by the mutual action of the
jet flows of the two flow-restrictions. Variations (deviations) in
the short fibers (3) are suppressed in the wind channel (30),
thereby making it possible to fabricate artificial cotton which is
uniform in "Metsuke" (mass per unit area).
[0092] In addition, on the side of the sub flow path, by virtue of
a vortex flow resulting from the action of a current of air
discharged from the roll unit (10) and the aforesaid jet flow, it
becomes possible to prevent the short fibers (3) from lingering in
the vicinity of the wall surface and from adhering to the wall
surface. Furthermore, in the wind channel (30) the up-current of
air is suppressed by a jet flow on the side of the roll unit (10),
and the short fibers (3) will no longer fly out of the
apparatus.
[0093] Furthermore, since the short fiber stirring plate (32) is
arranged at a slope so that its lower end (33a) opposite to the
roll unit (10) is low-lying, this arrangement makes it possible to
control the volume of air flowing on the side of the main flow path
and the volume of air flowing on the side of the sub flow path by
making a change in the sloping angle. This therefore makes it
possible to control the strength of ajet flow and the strength of a
vortex flow with ease.
[0094] And, with respect to the needle blade roll (12), if the
needle blades (14) are implanted at right angles (along the radial
direction) relative to the circumferential surface of the roll main
body (13) or are inclined backwardly relative to the rotational
direction, then the action of cutting of the needle blades (14) on
the fiber material (2) within the casing (11) tends to increase. As
a result, the length of short fibers (3) formed from the fiber
material (2) becomes shorter, therefore arising the possibility
that the intertwining of the short fibers (3) becomes difficult. In
the present invention, however, each needle blade (14) is inclined
against an associated radial line of the roll main body (13) so
that its leading end lies ahead of the radial line with respect to
the rotational direction of the needle blade roll (12). As a result
of such arrangement, the length of time of the "biting" of the
needle blade (14) into the fiber material (2) is prolonged, thereby
eliminating the tendency that the length of short fibers (3)
becomes shorter. Accordingly, it is possible to provide short
fibers (3) having a relatively longer length dimension, so that
when fabricating artificial cotton by accumulation of a large
number of short fibers (3) there is generated an action of causing
the short fibers (3) to be intertwined sufficiently with one
another. As the result of this, it becomes possible to fabricate
artificial cotton superior in strength.
Modification Examples of Embodiment
Modification Example 1
[0095] Referring to FIG. 9, there is shown a modification example
of the foregoing embodiment. In this example, the front-to-rear
direction of the wind channel (30) is the reversal of the foregoing
embodiment, and the roll unit (10) is fixed to the rear plate
(30b). And, the rear plate (30b) is formed by inverting a member
identical with the front plate (30a) of the foregoing embodiment
back and forth (horizontally relative to the figure). On the other
hand, the front plate (30a) is formed by back and forth inversion
of a member identical with the rear plate (30b) of the forgoing
embodiment. In addition, the short fiber stirring plate (32) is
disposed at a symmetrical position with respect to the foregoing
embodiment, and the lower end (33a) on the side of the surface
(30a) facing the roll unit (10) is lower-lying than the end portion
thereof on the side of the roll tnit (10) and than the leading end
(34a) of the vortex flow creating plate (34), which is the same as
the forgoing embodiment.
[0096] Other configurations and operation/working effects are the
same as the aforesaid embodiment.
Modification Example 2
[0097] Referring to FIG. 10, there is shown a second modification
example of the foregoing embodiment. In this example, in the casing
(11) of the roll unit (10) the discharge outlet (11b) is widened
towards the upper casing (11c). And, a second vortex flow creating
plate (11g) is fixed to an end of the upper casing (11c) on the
side of the discharge outlet (11b). The second vortex flow creating
plate (11g) lies substantially parallel with the front plate (30a)
of the wind channel (30). In other words, in the second
modification example, the second vortex flow creating plate (11g)
is provided atop the roll unit (10) below an air inflow opening
(30e) of the wind channel (30).
[0098] The discharge outlet (11b) of the casing (11) is made wider
as described above, thereby facilitating the discharge of short
fibers (3) into the wind channel (30) even when short fibers (3)
are being intertwined with the needle blade (14). On the other
hand, if the discharge outlet (11b) is just made wide, this arises
the possibility that short fibers (3) discharged from the top of
the discharge outlet (11b) flow out of the apparatus. In this
example, however, the upper casing (11c) is provided with the
second vortex flow creating plate (11g) and the vortex flow
creating plate (11g) is disposed atop the roll unit (10),
underlying the air inflow opening (30e) of the wind channel (30).
As a result of such arrangement, short fibers (3) are sucked in a
vortex flow created by the second vortex flow creating plate (11g)
on the wind channel's (30) side, they ride a current of air flowing
through the sub flow path and are brought back into the wind
channel (30). This prevents the short fibers (3) from flying out of
the apparatus.
[0099] Industrial Applicability
[0100] As has been described above, the present invention is useful
for a needle blade roll for artificial cotton fabricating
apparatuses.
* * * * *