U.S. patent application number 13/749722 was filed with the patent office on 2014-07-03 for method of producing cleaning member.
This patent application is currently assigned to UNICHARM CORPORATION. The applicant listed for this patent is UNICHARM CORPORATION. Invention is credited to Hiroaki GOTO, Takayuki MATSUMOTO, Shigetomo TAKAHASHI, Yuji YAMASHITA.
Application Number | 20140182767 13/749722 |
Document ID | / |
Family ID | 51015796 |
Filed Date | 2014-07-03 |
United States Patent
Application |
20140182767 |
Kind Code |
A1 |
GOTO; Hiroaki ; et
al. |
July 3, 2014 |
METHOD OF PRODUCING CLEANING MEMBER
Abstract
To provide a novel production method and a novel production
system that are suitable for producing a cleaning member having an
excellent cleaning performance and that realize efficient
production. The present invention is a method of producing a
cleaning member obtained from a multi-layer web comprising at least
a fiber bundle and a belt-shaped nonwoven fabric, wherein the
method comprises at least the step of connecting the ends of the at
least two the fiber bundles by melt-bonding.
Inventors: |
GOTO; Hiroaki; (Kanonji-shi,
JP) ; MATSUMOTO; Takayuki; (Kanonji-shi, JP) ;
TAKAHASHI; Shigetomo; (Kanonji-shi, JP) ; YAMASHITA;
Yuji; (Kanonji-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNICHARM CORPORATION |
Shikokuchuo-shi |
|
JP |
|
|
Assignee: |
UNICHARM CORPORATION
Shikokuchuo-shi
JP
|
Family ID: |
51015796 |
Appl. No.: |
13/749722 |
Filed: |
January 25, 2013 |
Current U.S.
Class: |
156/64 ;
156/304.6; 156/349; 156/378 |
Current CPC
Class: |
B32B 37/04 20130101;
A47L 13/38 20130101; A47L 13/16 20130101 |
Class at
Publication: |
156/64 ;
156/304.6; 156/349; 156/378 |
International
Class: |
B32B 37/04 20060101
B32B037/04 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 29, 2012 |
JP |
2012-289188 |
Claims
1. A method of producing a cleaning member obtained from a
multi-layer web comprising at least a fiber bundle and a
belt-shaped nonwoven fabric, said method comprising the steps of:
connecting the ends of at least two fiber bundles by melt-bonding;
opening said at least two fiber bundles; detecting the ends of said
connected at least two fiber bundles by a detecting part; forming a
multi-layer web by stacking; said at least two fiber bundles
including the ends of the connected at least two fiber bundles, the
ends being detected by the detecting part, and the belt-shaped
nonwoven fabric; fixing the multi-layer web; cutting the
multi-layer web in a lateral direction; and ejecting the
multi-layer web comprising the ends of the cut at least two fiber
bundles.
2. (canceled)
3. (canceled)
4. (canceled)
5. The method according to claim 1, wherein the step of fixing the
multi-layer web is a melt-bonding step.
6. (canceled)
7. A system of producing a cleaning member obtained from a
multi-layer web containing at least a fiber bundle and a
belt-shaped nonwoven fabric, the system being at least equipped
with a device for connecting the ends of at least two fiber bundles
by melt-bonding.
8. The system according to claim 7, further equipped with a device
for opening the at least two fiber bundles after connecting the
ends of the at least two fiber bundles.
9. The system according to claim 7, further equipped with a device
for detecting the ends of the connected at least two fiber bundles
by the detecting part.
10. The system according to claim 9, further equipped with a device
for forming a multi-layer web by stacking the at least two fiber
bundles comprising the ends of the connected at least two fiber
bundles, the ends being detected by the detecting part, and the
belt-shaped nonwoven fabric, and a device for fixing the
multi-layer web.
11. The system according to claim 10, further equipped with a
device for cutting the fusion-bonded multi-layer web in the lateral
direction, and a device for ejecting the multi-layer web comprising
the ends of the cut at least two fiber bundles.
12. The method according to claim 1, wherein said step of
connecting comprises joining the end of one of said at least two
fiber bundles on an outer surface of the end of the other of said
at least two fiber bundles.
13. The method according to claim 1, wherein said ends of said
connected at least two fiber bundles are not opened at said step of
detecting by the detecting part.
14. The method according to claim 1, wherein the detecting part is
located within a width of the at least two fiber bundles.
Description
TECHNICAL FIELD
[0001] The present invention relates to a method of producing a
cleaning member, and a system of producing a cleaning member.
BACKGROUND ART
[0002] Various types of cleaning members capable of trapping dust,
trash, etc., are conventionally known, and methods for producing
the various types have been examined from a variety of
viewpoints.
[0003] For example, Patent Document 1 proposes a method of
producing a cleaning member comprising the steps of: [0004]
stacking a belt-shaped inner fibrous layer consisting of continuous
fiber bundles and a belt-shaped sheet member, both being partially
joined to form a first continuous body, followed by the formation
of a second continuous body in a similar manner, and, after the
first and the second continuous bodies are stacked and partially
fixed, stacking and fixing a belt-shaped outer fibrous layer
consisting of continuous fiber bundles on each of the inner fibrous
layer side of the first and the second continuous bodies; [0005]
cutting the laminate obtained in the preceding step into a
predetermined length; and [0006] applying a compressed air to the
fibrous layer part of the cut laminate to open the fiber bundles;
[0007] wherein the belt-shaped inner fibrous layer and outer
fibrous layer are each composed of fiber bundles consisting of
curled fibers bent in a zig-zag form, a vertical height between the
alternating peaks and troughs of the above curled fiber is 0.1 to
0.7 mm, and, during the step of opening the above fiber bundles,
the fiber bundles in the cut laminate are teased so that the entire
periphery of the cleaning member is covered with brush tips
consisting of the fiber of the fiber bundles.
[0008] Also, Patent Document 2, for example, proposes a method of
producing a cleaning member, wherein [0009] a first continuous body
having a first fibrous layer consisting of continuous fiber bundles
and a first belt-shaped member, in which both longitudinal ends of
the first belt-shaped member are folded to be stacked and fixed,
and the first fibrous layer is stacked on and fixed to the outer
face side of the first belt-shaped member, and a second continuous
body having a second fibrous layer consisting of continuous fiber
bundles and a second belt-shaped member, in which both longitudinal
ends of the second belt-shaped member are folded to be stacked and
fixed, and the second fibrous layer is stacked and fixed onto the
outer face side of the second belt-shaped member, are produced, and
after the first continuous body and the second continuous body thus
produced are stacked and joined to each other, a third fibrous
layer and a fourth fibrous layer, each consisting of continuous
fibrous bundles, are stacked on the first fibrous layer and the
second fibrous layer, respectively, and fixed to form a laminate,
then the laminate thus formed is cut to obtain individual cleaning
members, [0010] characterized in that the method comprises the
steps of: [0011] intermittently forming broken guide lines spanning
the entire lateral area of each of the first belt-shaped member and
the second belt-shaped member in the first belt-shaped member and
the second belt-shaped member so that a central part sandwiched by
a pair of broken guide lines and an external part provided
consecutively in the central part via the broken guide lines are
formed in each of the first belt-shaped member and the second
belt-shaped member, respectively; [0012] joining the first
belt-shaped member and the second belt-shaped member, after forming
the broken guide lines, to the first fibrous layer and the second
fibrous layer with a central continuous seal line spanning the
entire lateral area of each of the first fibrous layer and the
second fibrous layer to produce the first continuous body and the
second continuous body; [0013] stacking the first continuous body
and the second continuous body to join them with side noncontinuous
seals spanning the entire lateral area of the first fibrous layer
and the second fibrous layer; [0014] further stacking and fixing a
third fibrous layer and a fourth fibrous layer onto the first
fibrous layer of the first continuous body and the second fibrous
layer of the second continuous body to form the laminate; [0015]
excising the external part flanking the central part, leaving the
central part sandwiched by the pair of broken guide lines, from
each of the cut first belt-shaped member and the cut second
belt-shaped member, after cutting the laminate; and [0016] opening
the cut first through fourth fibrous layers, so as to tease them
randomly in three-dimensional directions, after cutting the
laminate.
[0017] Furthermore, Patent Document 3, for example, proposes a
method of producing a cleaning member comprising the steps of:
[0018] laminating a continuous body comprising a four-layered long
fibrous layer in which fiber bundles are oriented in one direction,
a continuous body comprising two long scraping sheets, and a
continuous body comprising two long base sheet in the order of the
continuous body comprising the fibrous layer, the continuous body
comprising the scraping sheets, the continuous body comprising the
fibrous layer, the continuous body comprising the two base sheets,
the continuous body comprising the fibrous layer, the continuous
body comprising the scraping sheets, and the continuous body
comprising the fibrous layer, [0019] joining the continuous bodies
with one another at a predetermined distance in the lateral
direction to prepare a cleaning member continuous body, and then
[0020] cutting, in the lateral direction, the cleaning member
continuous body at the junctions between the continuous body of the
fibrous layer and the continuous body of the base sheet and the
continuous body of the scraping sheet to obtain a plurality of the
cleaning member.
CITATION LIST
Patent Literature
[0020] [0021] [PTL 1] U.S. Pat. No. 4,878,988 [0022] [PTL 2] U.S.
Pat. No. 4,738,311 [0023] [PTL 3] U.S. Pat. No. 4,675,218
SUMMARY OF INVENTION
Technical Problem
[0024] However, there is currently a need for a novel production
method and a production system of producing cleaning members
capable of trapping dust, trash, etc., in a more efficient manner.
Considering the above circumstance, the present invention was found
by the present inventors as a result of intensive and extensive
investigation.
[0025] Thus, it is an object of the present invention to provide a
novel production method and a novel production system that are
suitable for producing a cleaning member having excellent cleaning
performance and that realize efficient production.
Solution to Problem
[0026] In order to obtain the above objective, the present
invention provides a method of producing a cleaning member obtained
from a multi-layer web comprising at least a fiber bundle and a
belt-shaped nonwoven fabric, wherein the method of producing the
cleaning member comprises at least the step of connecting the ends
of at least two the fiber bundles.
Effects of Invention
[0027] In accordance with the present invention, a novel production
method and a novel production system that are suitable for
producing a cleaning member having an excellent cleaning
performance and that realize efficient production is provided.
BRIEF DESCRIPTION OF DRAWINGS
[0028] FIG. 1 is a perspective view of a cleaning member produced
by an embodiment of the production method and/or production system
of the present invention and a holding tool that is fixed to the
cleaning member.
[0029] FIG. 2 is a sectional view of FIG. 1 along a X-X line.
[0030] FIG. 3 is a plan view of the cleaning member shown in FIG.
1.
[0031] FIG. 4 is a schematic view for explaining a method and/or a
system of producing the cleaning member shown in FIG. 1.
[0032] FIG. 5 is a view that illustrates an embodiment of the
production method and/or the production system of the present
invention.
[0033] FIG. 6 is a view that schematically illustrates a state in
which the ends of two fiber bundles are connected.
[0034] FIG. 7 is a view that illustrates an embodiment of a step in
which a phototube is used for detection and/or a device in which a
phototube is used for detection.
DESCRIPTION OF EMBODIMENTS
Method of Producing a Cleaning Member
[0035] The method of producing the cleaning member of the present
invention will now be explained in detail below.
[0036] The method of producing a cleaning member according to the
present invention is a method of producing a cleaning member
obtained from a multi-layer web comprising at least a fiber bundle
and a belt-shaped nonwoven fabric, [0037] wherein the method
comprises at least the step of connecting the ends of at least two
fiber bundles by melt-bonding (aspect 1).
[0038] The method of producing a cleaning member according to the
present invention is a novel production method that is suitable for
producing a cleaning member having excellent cleaning performance
and that realizes efficient production. The method of producing a
cleaning member according to the present invention can continuously
supply fiber bundles and thus excels in high-speed production and
further in continuous production.
[0039] In aspect 1, as a step after the step of connecting the ends
of at least two fiber bundles, it may be preferable to further
comprise the step of opening the at least two fiber bundles (aspect
2). According to aspect 2, after connecting the ends of at least
two fiber bundles, at least two fiber bundles are opened, which
makes it easy to detect the connected ends without opening them
with a phototube.
[0040] In aspect 1 or 2, it may be preferable to further comprise a
detection step in which the ends of the above connected at least
two fiber bundles are detected by a detecting part (aspect 3). The
detecting part may preferably be disposed before the step of
forming a multi-layer web by stacking fiber bundles described below
and the above belt-shaped nonwoven fabric. As the detecting part,
for example, a phototube, a camera etc. may be mentioned. In a
phototube, a light-emitting part and a light-receiving part are
disposed at a predetermined lateral position sandwiching a fiber
bundle and a non-contacting fiber bundle, and a detecting means
integrated with the light-emitting/light-receiving part is disposed
at a predetermined lateral position of a fiber bundle and a
non-contacting fiber bundle. The camera detects the position of the
ends of fiber bundles by binarizing an image input by the camera
using predetermined parameters.
[0041] In aspect 3, it may be preferable to further comprise a step
of forming a multi-layer web by stacking the above at least two
fiber bundles comprising the ends of the above connected at least
two fiber bundles, the ends being detected by the above detecting
part, and the above belt-shaped nonwoven fabric, and a step of
fixing the multi-layer web (aspect 4).
[0042] In aspect 4, the step of fixing the multi-layer web may
preferably be a melt-bonding step (aspect 5). In another
embodiment, the fixing step is a step of fixing by hot-melt.
[0043] In aspect 4 or 5, it may be preferable to further comprise a
step of cutting the fusion-bonded multi-layer web in the lateral
direction, and a step of ejecting the multi-layer web comprising
the above ends of the above cut at least two fiber bundles (aspect
6).
[0044] In the method of producing a cleaning member according to
the present invention, two or more of aspects 1 through 6 can be
combined.
(System of Producing a Cleaning Member)
[0045] The system of producing a cleaning member according to the
present invention will now be explained in detail below.
[0046] The system of producing a cleaning member according to the
present invention is a system of producing a cleaning member that
is obtained from a multi-layer web containing a fiber bundle and a
belt-shaped nonwoven fabric, the system being at least equipped
with a device for connecting the ends of at least two fiber bundles
by melt-bonding (aspect 7).
[0047] The system of producing a cleaning member according to the
present invention is a novel production system that is suitable for
producing a cleaning member having an excellent cleaning
performance and that realizes efficient production. The system of
producing a cleaning member according to the present invention can
continuously supply fiber bundles, and thus excels in high-speed
production and further in continuous production.
[0048] In aspect 7, it may be preferable to be further equipped
with a device for opening at least two fiber bundles after
connecting the ends of the at least two fiber bundles (aspect 8).
According to aspect 8, the at least two fiber bundles are opened
after the ends of the at least two fiber bundles were connected,
and thus it becomes easier to detect the connected ends without
opening the bundles with a phototube, etc.
[0049] In aspect 7 or 8, it may be preferable to be further
equipped with a device for detecting the ends of the connected at
least two fiber bundles by the detecting part (aspect 9). The
detecting part may preferably be disposed before the step of
forming a multi-layer web by stacking fiber bundles described below
and the above belt-shaped nonwoven fabric. As the detecting part,
for example, a phototube, a camera etc. may be mentioned. In a
phototube, a light-emitting part and a light-receiving part are
disposed at a predetermined lateral position sandwiching a fiber
bundle and a non-contacting fiber bundle, and a detecting means
integrated with the light-emitting/light-receiving part is disposed
at a predetermined lateral position of a fiber bundle and a
non-contacting fiber bundle. The camera detects the position of the
ends of fiber bundles by binarizing an image input by the camera
using predetermined parameters.
[0050] In aspect 9, it may be preferable to be further equipped
with a device for forming a multi-layer web by stacking the above
at least two fiber bundles comprising the ends of the above
connected at least two fiber bundles, the ends being detected by
the above detecting part, and the above belt-shaped nonwoven
fabric, and a device of melt-bonding the multi-layer web (aspect
10).
[0051] In aspect 10, it may be preferable to be further equipped
with a device for cutting the fusion-bonded multi-layer web in the
lateral direction, and a device for ejecting the multi-layer web
comprising the above ends of the above cut at least two fiber
bundles (aspect 11).
[0052] In the system of producing a cleaning member according to
the present invention, two or more of aspects 7 through 11 can be
combined.
[0053] Embodiments of the method and the system of producing a
cleaning member according to the present invention are explained in
more detail with reference to FIG. 1 through FIG. 7. The method and
the system of producing a cleaning member according to the present
invention are not limited to the embodiments of the present
invention represented by FIG. 1 through FIG. 7 in a range without
departing from the scope and spirit of the present invention.
[0054] First, a cleaning member 1 will be explained with reference
to FIG. 1 through FIG. 3.
[0055] FIG. 1 is a perspective view of a holding tool that is fixed
to the cleaning member 1, FIG. 2 is a sectional view of FIG. 1
along the X-X line, and FIG. 3 is a plan view of the cleaning
member 1 shown in FIG. 1. In the explanation below, while "top" may
be referred to as an upper side and "bottom" as a downside in FIG.
2, "top" and "bottom" in FIG. 2 are only used for the sake of
explanation, and do not intend to limit the actual upper or lower
direction of the cleaning member 1.
[0056] As shown in FIG. 1 through FIG. 3, the cleaning member 1 is
equipped with a brush sheet 2, a base sheet 12 stacked on the upper
side of the brush sheet 2, and a holding sheet 13 stacked on the
upper side of the base sheet 12.
[0057] As shown in FIG. 1 through FIG. 3, in the cleaning member 1,
a receiving part 14 into which the insertion part 16 of a holding
tool 15 is to be inserted has been formed in between the base sheet
12 and the holding sheet 13. As shown in FIG. 1 through FIG. 3, in
the cleaning member 1, two receiving parts 14 have been formed so
as to receive the insertion part 16 that was divided into two.
While the number of the receiving parts 14 in this embodiment is
two, the number of the receiving parts can be changed as
appropriate depending on the number of divisions of the insertion
part 16. In another embodiment, there may be mentioned an
embodiment in which the number of the insertion parts 14 is three
or more.
[0058] As shown in FIG. 2, the brush sheet 2 has a fibrous member
of a four-layer structure comprising a first fibrous member 3, a
second fibrous member 4 stacked at the downside of the first
fibrous member 3, a third fibrous member 5 stacked at the downside
of the second fibrous member 4, and a fourth fibrous member 6
stacked at the downside of the third fibrous member 5, and a sheet
with slits 7 stacked at the downside of the four-layer structured
fibrous member (at the downside of the fourth fibrous member 6).
The fibrous member of the brush sheet 2 according to the present
embodiment has a four-layer structure, but the layer structure of
the fibrous member can be changed as appropriate. In another
embodiment, there may be mentioned an embodiment in which the
fibrous member has a one-layer structure, a two-layer structure or
a three-layer structure, and in still another embodiment, the
fibrous member has a structure of five-layer or more. Also, while
the brush sheet 2 in the present embodiment has a sheet with slits
7, the presence or absence of the sheet with slits 7 may be
selected as appropriate. In another embodiment, the sheet with
slits 7 has been omitted.
[0059] The first through fourth fibrous members 3 through 6 are
fiber bundles to which an oil solution is attached, and thus is a
dust adhering agent (for example, an oil solution comprising liquid
paraffin as an active ingredient) having an effect of promoting the
adherence of dust, trash, etc.
[0060] A fiber bundle is, for example, a tow, preferably an opened
tow. As described in JIS L 0204-3:1998, 3.1.24, "tow" indicates a
bundle of an extremely large number of filaments.
[0061] A fiber bundle may be a bundle of slit fibers (fibers made
by cutting a film into reed-shaped part and then stretching them),
split fiber (fibers made by subdividing reed-shaped parts of film
into a network structure), etc.
[0062] As fiber bundles, there can be mentioned, for example, fiber
bundles consisting of or comprising thermoplastic fibers, etc. As
raw materials constituting fiber bundles, there can be mentioned,
for example, polyethylene, polypropylene, polyethylene
terephthalate, nylon, rayon, etc., and the type of fibers
constituting fiber bundles include, for example, single fibers,
composite fibers (for example, core-in-sheath composite fibers,
side-by-side composite fibers), etc. From the viewpoint of thermal
bondability, composite fibers may preferably be core-sheath type
composite fibers, and more preferably core-sheath type composite
fibers in which the melting point of the core is higher than that
of the sheath.
[0063] As a preferred core-in-sheath composite fiber, there can be
mentioned core-sheath type composite fibers in which the core
consists of polypropylene or polyethylene terephthalate and the
sheath consists of polyethylene, and more preferably core-sheath
type composite fibers in which the core consists of polyethylene
terephthalate and the sheath consists of polyethylene.
[0064] The purity of a fiber constituting fiber bundles may
preferably be 1-500 dtex, more preferably 2-10 dtex. Fiber bundles
may comprise a plurality of fibers having the same purity, or a
single fiber or a plurality of fibers having a different
purity.
[0065] In the present embodiment, each fiber constituting fiber
bundles is composed of curled fibers. By allowing each fiber to be
composed of curled fibers, fiber bundles can be made bulky and can
be made a structure that permits easy trapping of dust etc. at the
curled parts. In another embodiment, there can be mentioned an
embodiment in which each fiber constituting fiber bundles is
composed of noncurled fibers.
[0066] Similarly to the base sheet 12 and the holding sheet 13, as
described below, the sheet with slits 7 is composed of a nonwoven
fabric consisting of a thermoplastic fiber (a thermally
fusion-bondable fiber) or a nonwoven fabric comprising a
thermoplastic fiber, and is formed in a rectangular shape of the
same width and the same length as those of the base sheet 12. In
the sheet with slits 7, saw-edged cuts (not shown) are made at a
given distance along the entire sheet with slits 7, and with the
cuts, saw-edged reed-shaped parts (not shown) are formed over the
entire length along both lateral ends of the sheet with slits
7.
[0067] As shown in FIG. 1 through FIG. 3, a base sheet 12 and a
holding sheet 13 are stacked sequentially on the upper side of the
first fibrous member 3 of the brush sheet 2, and a receiving part
14 into which the insertion part 16 of the holding tool 15 is to be
inserted is formed in between the base sheet 12 and the holding
sheet 13.
[0068] As shown in FIG. 3, the base sheet 12 and the holding sheet
13 have a rectangular form, and the lateral dimension (the
direction of left to right in FIG. 3) of both sheets is set to be
the same, and the longitudinal dimension (the vertical direction in
FIG. 3) is set to be longer in the base sheet 12 so that both
longitudinal ends of the base sheet 12 protrudes by a predetermined
length from both longitudinal ends of the holding sheet 13, with
the holding sheet 13 being stacked on the upper side of the base
sheet 12.
[0069] The base sheet 12 and the holding sheet 13 are made of a
nonwoven fabric consisting of a thermoplastic fiber (thermally
fusion-bondable fiber) or a nonwoven fabric comprising a
thermoplastic fiber. As thermoplastic fibers, for example, a
polyethylene fiber, a polypropylene fiber, a polyethylene
terephthalate fiber, a composite fiber of polyethylene and
polyethylene terephthalate, and a composite fiber of polyethylene
and polypropylene, such as core-sheath type composite fibers in
which the core is composed of polyethylene terephthalate and the
sheath is composed of polyethylene can be mentioned. As the type of
nonwoven fabric, for example, a thermal bond nonwoven fabric, a
spunbonded nonwoven fabric, a spunlace nonwoven fabric and the like
can be mentioned.
[0070] In another embodiment, there can be mentioned an embodiment
in which the base sheet and the holding sheet are made of a
thermoplastic resin film such as a polyethylene film and a
polypropylene film, and in still another embodiment, the base sheet
and the holding sheet are made of a laminate sheet comprising a
nonwoven fabric and a resin film.
[0071] The base sheet 12 and the holding sheet 13 are integrally
fusion-bonded to all the layers (the first fibrous member 3, the
second fibrous member 4, the third fibrous member 5, the fourth
fibrous member 6, and the sheet with slits 7) of the brush sheet 2
through a first melt bonded part forming device 158 described
below, and in the cleaning member 1, a first melt-bonding part 8
longitudinally extending in the central part is formed as shown in
FIG. 1 through FIG. 3. Furthermore, at both ends (lateral ends in
FIG. 2) of the first melt-bonding part 8, the base sheet 12 and the
holding sheet 13 are integrally bonded to one layer (the first
fibrous member 3) of the brush sheet 2 through a second melt bonded
part forming device 134 described below, and in the cleaning member
1, two second melt-bonding parts 11 are longitudinally formed. Each
of the two second melt-bonding parts 11 is intermittently formed.
Since the first fibrous member 3 is fusion-bonded to the base sheet
12 and the holding sheet 13, the first fibrous member 3 follows the
movement of these sheets 12 and 13, and thus the brush sheet 2
tends to further expand during use, resulting in an improved
cleaning efficiency.
[0072] The base sheet 12 and the holding sheet 13 are fusion-bonded
to all the layers (the first fibrous member 3, the second fibrous
member 4, the third fibrous member 5, the fourth fibrous member 6,
and the sheet with slits 7) of the brush sheet 2 in the first
melt-bonding part 8, and are fusion-bonded to the first fibrous
member 3 of the brush sheet 2 in two second melt-bonding parts 11.
This results in the formation of a pair of receiving parts 14,
which extends in the longitudinal direction of the base sheet 12
and the holding sheet 13 and which is a saclike space opening on
both longitudinal ends, compartmentalized by the first melt-bonding
part 8 and two second melt-bonding parts 11, thereby enabling the
insertion part 16 of the holding tool 15 to be inserted into the
receiving part 14.
[0073] The base sheet 12 and the holding sheet 13 are fusion-bonded
to the first fibrous member 3 of the brush sheet 2 at the central
part thereof through a second melt bonded part forming device 134
described below, and in the cleaning member 1, a pair of
melt-bonding lines 18 are formed at a predetermined distance in the
lateral direction of the base sheet 12 and the holding sheet 13, as
shown in FIG. 3, with a first melt-bonding part 8 being formed in
between the pair of melt-bonding lines 18. The pair of melt-bonding
lines 18 are a landmark for monitoring the position of the first
melt-bonding part 8 during the production step, and by monitoring
whether the first melt-bonding part 8 is disposed in between the
pair of the thermal melt-bonding lines 18 with a sensor etc., good
items and defective items can be sorted out.
[0074] As shown in FIG. 1 through FIG. 3, two second melt-bonding
parts 11 are intermittently provided at several places in the
longitudinal direction of the base sheet 12 and the holding sheet
13, and by engaging an arc-like protrusion 16a at each insertion
part 16 of the holding tool 15 with the non-fusion-bonded part of
the two second melt-bonding parts 11, each insertion part 16 of the
holding tool 15 is prevented from coming off each receiving part
14.
[0075] As shown in FIG. 1, saw-edged slits 20a are provided at each
given distance along the longitudinal direction in both lateral
ends (the external parts of two second melt-bonding parts 11) of
the base sheet 12 and the holding sheet 13, and with the slits 20a,
a plurality of reed-shaped parts 20, both ends of which are
saw-edged, are provided. In another embodiment, there can be
mentioned an embodiment in which no saw-edged slits 20a are
provided in the base sheet 12 and the holding sheet 13, and thus
reed-shaped parts 20 are not provided.
[0076] As shown in FIG. 1, the holding tool 15 has a pair of
rectangular plate-shaped insertion parts 16 disposed in parallel to
each other, a pair of arc-like protrusions 16a protruding from the
outer face of both longitudinal ends of each insertion part 16, and
a holder part 17 provided integrally on one end of the insertion
part 16, and is made, for example, of plastic etc.
[0077] By inserting both insertion parts 16 of the holding tool 15
into both insertion parts 14 of the cleaning member 1, and engaging
the protrusions 16a with two second melt-bonding parts 11, the
cleaning member 1 can be mounted to the holding tool 15. By holding
the holder part 17 of the holding tool 15, and allowing the brush
sheet 2 to come into contact with a target cleaning site to move it
in the desired direction, dust, etc., at the target cleaning site
are trapped by the brush sheet 2, resulting in the cleaning of the
target cleaning site.
[0078] The cleaning member shown in FIG. 1 through FIG. 3 is an
example of a cleaning member that can be produced by the method and
system of producing a cleaning member according to the present
invention. The method of producing a cleaning member and the system
of producing a cleaning member according to the present invention
can be used in producing cleaning members as described in, for
example, Japanese Unexamined Patent Publication Nos. 2000-296083,
2003-265390, 2003-268663, 2004-223692, 2005-046645, 2005-095665,
2005-111284, 2005-137929, 2005-137930, 2005-137931, 2005-144198,
2005-169148, 2005-199077, 2005-230573, 2005-237975, 2006-015164,
2006-034990, 2006-141483, 2007-135774, 2007-209460 and 2007-209461,
2007-029136, 2007-111297, 2007-135666, 2007-136156, 2007-159612,
2007-236690, 2008-006260, 2008-119171, and 2007-029135, the entire
disclosures of which are incorporated herein by reference. The
method of producing a cleaning member and the system of producing a
cleaning member according to the present invention can be used to
produce a cleaning member as described in, for example, U.S. Pat.
No. 6,554,937B, US2002/148061A, US2003/0000934A, US2004/0149095A,
US2005/0005381A, US2005/039285A, US2005/097695A, US2005/097696A,
US2005/132521A, US2005/177967A, US2005/188490A, US2005/193513A,
US2005/193514A, US2005/198760A, US2006/016035A, US2006/016036A,
US2006/101601A, US2009/165230A and US2009/172904A, as well as
US2009/049633A, US2009/255078A and US2010/154156A, the entire
disclosures of which are incorporated herein by reference.
[0079] Next, an embodiment of a method and a device for producing a
cleaning member 1 will be explained with reference to FIG. 4.
[0080] FIG. 4 is a schematic view for explaining a method and the
device for producing a cleaning member 1, and in the present
embodiment, the method of producing the cleaning member 1 is
carried out using a device 100 shown in FIG. 4 to produce the
cleaning member 1.
[0081] In the present embodiment, the method of producing the
cleaning member 1 comprises the following step 1 and step 2.
[0082] [Step 1] A step of opening a fiber bundle--a step of
conveying it.
[0083] [Step 2] A step of producing a multi-layer web using fiber
bundles and excising (cutting out) the cleaning member 1 from the
multi-layer web.
<Step 1>
[0084] Hereinbelow, step 1 will be explained.
[0085] In the present embodiment, step 1 comprises the following
step 1a and step 1b.
[0086] [Step 1a] A step of opening a first fiber bundle F1 through
a fourth fiber bundle F4.
[0087] [Step 1b] A step of conveying the first fiber bundle F1
through the fourth fiber bundle F4.
[0088] According to the present embodiment, while step 1 comprises
step 1a, the presence or absence of step 1a can be selected as
appropriate depending on the type etc. of the fiber bundle used. In
another embodiment, an embodiment in which step 1a is omitted can
be mentioned. For example, when fiber bundles are composed of a
noncurled fiber, step 1a can be omitted.
[0089] [Step 1a]
[0090] Hereinbelow, step 1a will be explained with reference to a
step of opening the first fiber bundle F1 by way of example, and
steps of opening other fiber bundles can be carried out in a
similar manner.
[0091] The first fiber bundle F1 composed of a curled fiber is
continuously extracted from a housing container (not shown), and
conveyed to first nip rolls 102a and 102b revolving at a constant
peripheral velocity V1. The first fiber bundle F1 that passed
through the first nip rolls 102a and 102b passes through a
plurality of tension rolls 104, and is conveyed to second nip rolls
106a and 106b revolving at a peripheral velocity V2.
[0092] The peripheral velocity V2 of the second nip rolls 106a and
106b is faster than the peripheral velocity V1 of the first nip
rolls 102a and 102b. Due to the difference in the rim speed,
tension is imparted to the first fiber bundle F1 between the first
nip rolls 102a and 102b and the second nip rolls 106a and 106b,
resulting in the opening of the first fiber bundle F1.
[0093] Each tension roll 104 is formed, for example, of a solid
steel, and the weight has been adjusted to require a significant
degree of force for revolving. Thus, during the movement of the
first fiber bundle F1, while rotating each tension roll 104, from
the first nip rolls 102a and 102b toward the second nip rolls 106a
and 106b, the moving speed of the first fiber bundle F1 has been
adjusted not to increase abruptly.
[0094] In order to attain the gradual opening of the first fiber
bundle F1, each tension roll 104 has been disposed so as to
lengthen the distance between the first nip rolls 102a and 102b and
the second nip rolls 106a and 106b.
[0095] The first fiber bundle F1 that passed through the second nip
rolls 106a and 106b passes through an air supplier 108 and is
conveyed to third nip rolls 112a and 112b. The peripheral velocity
V3 of the third nip rolls 112a and 112b is slower than the
peripheral velocity V2 of the second nip rolls 106a and 106b. Due
to the difference in the rim speed, tension of the first fiber
bundle F1 is relieved between the second nip rolls 106a and 106b
and the third nip rolls 112a and 112b, resulting in the opening of
the first fiber bundle F1 as well as the widening of the width of
the first fiber bundle F1.
[0096] On the first fiber bundle F1 that is conveyed from the
second nip rolls 106a and 106b to the third nip rolls 112a and
112b, air is blown from the air supplier 108, resulting in the
further opening of the first fiber bundle F1.
[0097] According to the present embodiment, while the first fiber
bundle F1 is opened using the application and release of tension
and air blowing, the method of opening can be changed as
appropriate. In another embodiment, there can be mentioned an
embodiment in which either of the application and release of
tension or air blowing is used, and in still another embodiment,
there can be mentioned an embodiment in which another method of
opening is used in addition to the application and release of
tension and air blowing. Also in the present embodiment, while the
first through third nip rolls are used in the application and
release of tension, the number of nip rolls can be changed as
appropriate. In another embodiment, there can be mentioned an
embodiment in which additional nip rolls are used for the
application and release of tension in addition to the first through
third nip rolls.
[0098] An oil solution is contained in an oil solution tank 114. In
the present embodiment, the oil solution contained in the oil
solution tank 114 is a dust-adhering oil solution (such as an oil
solution comprising liquid paraffin as an active ingredient) having
an effect of promoting the adsorption of dust etc.
[0099] [Step 1b]
[0100] Hereinbelow, step 1b will be explained with reference to a
step of conveying the first fiber bundle F1 by way of example, and
a step of conveying other fiber bundles can be carried out in a
similar manner.
[0101] After passing through the third nip rolls 112a and 112b, the
first fiber bundle F1 passes through a first phototube 181, and
proceeds to a merging part 132. Similarly, the second through the
fourth fiber bundles F2 through F4, after passing through the third
nip rolls (not shown), pass through a second phototube 182, a third
phototube 183 and a fourth phototube 184, and proceeds to merging
parts 136, 138 and 140, respectively.
<Step 2>
[0102] Hereinbelow, step 2 will be explained.
[0103] In the present embodiment, step 2 comprises the following
step 2a through step 2c.
[0104] [Step 2a] A step of stacking a fiber bundle that underwent
through step 1b and another member (a belt-shaped nonwoven fabric
in the present embodiment) to form a multi-layer web.
[0105] [Step 2b] A step of fixing the fiber bundle and another
member contained in the multi-layer web.
[0106] [Step 2c] A step of excising individual cleaning members 1
from the multi-layer web.
[0107] [Step 2a]
[0108] Hereinbelow, step 2a will be explained.
[0109] In the present embodiment, the other members that are
stacked with the fiber bundles that underwent the step 1b are
belt-shaped nonwoven fabrics 121, 123 and 151. In another
embodiment, one or two of these belt-shaped nonwoven fabrics are
stacked with the fiber bundles that underwent the step 1b, and in
still another embodiment, another belt-shaped nonwoven fabric, in
addition to these belt-shaped nonwoven fabrics, is stacked with the
fiber bundles that underwent the step 1b. In any of the
embodiments, the order of stacking is not limited, but preferably
stacking may be carried out so that the belt-shaped nonwoven fabric
is positioned at the outermost layer.
[0110] The belt-shaped nonwoven fabrics 121 and 123 correspond to
the base sheet 12 and the holding sheet 13, respectively, of the
cleaning member 1. The belt-shaped nonwoven fabric 121 is
continuously curled out from an nonwoven fabric roll 120, and is
conveyed intermittently by passing through a dancer roll 124
comprising a plurality of rolls provided in two vertical stages
wherein a roll located at the lower stage fluctuates vertically.
Similarly, the belt-shaped nonwoven fabric 123 is continuously
curled out from an nonwoven fabric roll 122, and is conveyed
intermittently by passing through a dancer roll 126 comprising a
plurality of rolls provided in two vertical stages wherein a roll
located at the lower stage fluctuates vertically. As used herein
"is conveyed intermittently" means that the belt-shaped nonwoven
fabrics 121 and 123 are conveyed by repeating the steps of
proceeding by a given distance (for example, roughly the lateral
length of the cleaning member 1) and then stopping conveying for a
certain period of time. Thus, by the intermittent conveyance of the
belt-shaped nonwoven fabrics 121 and 123, the time required to
fusion-bond the constituent elements of the multi-layer web
described below can be secured.
[0111] The belt-shaped nonwoven fabrics 121 and 123 form a
multi-layer web S1 at a merging part 128, and the multi-layer web
S1 passes through a gather cutter 130 in which saw-edged blades
(not shown) are intermittently formed on the surface thereof in a
circumferential direction. This results in the formation of cuts
corresponding to cuts 20a (see FIG. 1) in the base sheet 12 and the
holding sheet 13. And the multi-layer web S1 proceeds to a merging
part 132.
[0112] At the merging part 132, the multi-layer web S1 merges with
the first fiber bundle F1 that underwent the step 1, and the first
fiber bundle F1 is stacked on the multi-layer web S1 to form a
multi-layer web S2. The first fiber bundle F1 is configured to
become loosened slightly in between the third nip rolls 112a and
112b and the merging part 132, and thus fulfills the same function
as a dancer roll provided between them would do.
[0113] At merging parts 136, 138 and 140, the multi-layer web S2
merges sequentially with the second fiber bundle F2 through the
fourth fiber bundle F4 that underwent the step 1, and the second
fiber bundle F2 through the fourth fiber bundle F4 are stacked
sequentially on the multi-layer web S2 to form a multi-layer web
S3.
[0114] A belt-shaped nonwoven fabric 151 corresponds to the sheet
with slits 7 of the cleaning member 1. The belt-shaped nonwoven
fabric 151 is continuously curled out from the nonwoven fabric roll
150, and is intermittently conveyed by passing through a dancer
roll 152, and then passes through a gather roll 154. The gather
roll 154 has saw-edged blades (not shown) continuously formed on
the surface of the roll in a circumferential direction, which
results in the formation of saw-edged cuts (not shown) on the
belt-shaped nonwoven fabric 151 that passed through the gather roll
154.
[0115] The belt-shaped nonwoven fabric 151 merges with the
multi-layer web S3 at a merging part 156, and the belt-shaped
nonwoven fabric 151 is stacked on the multi-layer web S3 to form a
multi-layer web S4.
[0116] [Step 2b]
[0117] Hereinbelow, step 2b will be explained.
[0118] Before merging with the second fiber bundle F2 through the
fourth fiber bundle F4, the multi-layer web S2 passes through a
second melt bonded part forming device 134. The second melt bonded
part forming device 134 fusion-bonds belt-shaped nonwoven fabrics
121 and 123 contained in the multi-layer web S2 to the first fiber
bundle F1 to form two second melt-bonding parts 11 (see FIG. 3).
This results in the melt-bonding of the multi-layer web S2 in the
direction of the thickness thereof. In the present embodiment,
while a heat sealing device is used as the second melt bonded part
forming device 134, another heat sealing device (such as an
ultrasonic sealing device) may be used.
[0119] The multi-layer web S4 passes through a first melt bonded
part forming device 158. The first melt bonded part forming device
158 fusion-bonds the entire hole multi-layer web S4 to form a first
melt-bonding part 8 (see FIG. 3) on the multi-layer web S4. This
results in the melt-bonding of the multi-layer web S4 in the
direction of the thickness thereof. In the present embodiment,
while a heat sealing device is used as the first melt bonded part
forming device 154, the heat sealing device can be changed as
appropriate. In another embodiment, an ultrasonic sealing device is
used.
[0120] [Step 2c]
[0121] Hereinbelow, step 2c will be explained. The multi-layer web
S4 that passed through the first melt bonded part forming device
158 is cut by a cutting device 160, so that individual cleaning
members 1 are excised. As described above, also, the multi-layer
web S4 comprising the ends of the above connected at least two
unopened fiber bundles, the ends being detected by the four
phototubes (181 through 184), is ejected by an ejecting device 190.
Since the distance from the detection point to the ejection point
is constant, the number (N) of products present in the distance can
be calculated by distance/length of the product. When a shortage in
the width is detected by the detecting part, a detection signal for
width shortage is input into a programmable logic controller (PLC),
in which the counting part of the PLC starts to add the number of
sheets. When the number reaches a predetermined number, the
ejecting device of the ejecting part is started to eject products
having defective width. If a product having a Nth product number is
only ejected, no defective product will enter into the finished
products. In order to carry out secure ejection, products having a
product number in the range of N.+-.2 (N-2, N-1, N, N+1, N+2), or
products having a product number in the range of N.+-.1 (N-1, N,
N+1) can be ejected.
[0122] The cleaning member 1 produced according to the present
embodiment contains the sheet with slits 7, whereas a cleaning
member produced by another embodiment does not contain the sheet
with slits 7. In the cleaning member 1 produced by the present
embodiment, the receiving part 14 is disposed on the face of the
cleaning member 1, whereas in a cleaning member produced by another
embodiment, the receiving part 14 is disposed in between any of
adjacent fibrous members 3 through 6 by changing the order of
stacking the base sheet 12 and the holding sheet 13 and the fibrous
members 3 through 6. This makes it possible to use both faces of
the cleaning member 1 in cleaning. At this time, in order to
facilitate the insertion of the insertion part 16 into the
receiving part 14, the longitudinal dimension (vertical dimension
in FIG. 3) of the base sheet 12 and the holding sheet 13 may
preferably be made longer than that of the fibrous members 3
through 6, and these dimensions can be arbitrarily determined.
Also, at this time, the sheet with slits 7 may or may not be used,
and the sheet with slits 7 may be disposed on both faces of the
cleaning member 1.
[0123] FIG. 5 is a drawing that schematically illustrates that the
first fiber bundle F1 in which ends b (the terminal end part of the
one first fiber bundle F1 and the starting end part of the other
first fiber bundle F1) of the first fiber bundle F1, each being
housed in two housing containers, is discharged. It can be
recognized that by fixing the ends b by melt-bonding such as heat
sealing and adhesion, continuous production can be realized.
[0124] FIG. 6 is a drawing that schematically illustrates the
enlargement of the ends b of two first fiber bundles F1. It can be
recognized that the fixing part (the heat sealing part in FIG. 6)
of the ends b is not opened even by undergoing the opening
step.
[0125] FIG. 7 is a drawing that schematically illustrates a state
in which the phototube 181 passes through the first fiber bundle F1
during the step of conveying the first fiber bundle F1.
[0126] The present application claims the benefit of the following
patent applications, the entire disclosures of which are
incorporated herein by reference: [0127] (1) JP Patent Application
No. 2012-289181 filed on Dec. 29, 2012, and US patent application
claiming priority thereof (filed on the same day as the present
application), [0128] (2) JP Patent Application No. 2012-289182
filed on Dec. 29, 2012, and US patent application claiming priority
thereof (filed on the same day as the present application), [0129]
(3) JP Patent Application No. 2012-289174 filed on Dec. 29, 2012,
and US patent application claiming priority thereof (filed on the
same day as the present application), [0130] (4) JP Patent
Application No. 2012-289189 filed on Dec. 29, 2012, and US patent
application claiming priority thereof (filed on the same day as the
present application) [0131] (5) JP Patent Application No.
2012-289175 filed on Dec. 29, 2012, and US patent application
claiming priority thereof (filed on the same day as the present
application), [0132] (6) JP Patent Application No. 2012-289188
filed on Dec. 29, 2012, [0133] (7) JP Patent Application No.
2012-289179 filed on Dec. 29, 2012, and US patent application
claiming priority thereof (filed on the same day as the present
application), [0134] (8) JP Patent Application No. 2012-289177
filed on Dec. 29, 2012, and US patent application claiming priority
thereof (filed on the same day as the present application), [0135]
(9) JP Patent Application No. 2012-289184 filed on Dec. 29, 2012,
and US patent application claiming priority thereof (filed on the
same day as the present application), [0136] (10) JP Patent
Application No. 2012-289178 filed on Dec. 29, 2012, and US patent
application claiming priority thereof (filed on the same day as the
present application), [0137] (11) JP Patent Application No.
2012-289176 filed on Dec. 29, 2012, and US patent application
claiming priority thereof (filed on the same day as the present
application), [0138] (12) JP Patent Application No. 2013-002855
filed on Jan. 10, 2013, and US patent application claiming priority
thereof (filed on the same day as the present application), as well
as [0139] (13) JP Patent Application No. 2013-002857 filed on Jan.
10, 2013, and US patent application claiming priority thereof
(filed on the same day as the present application).
REFERENCE SIGNS LIST
[0140] 1: cleaning member; 2: brush sheet (shaggy brush sheet); 3:
first fibrous member; 4: second fibrous member; 5: third fibrous
member; 6: fourth fibrous member; 7: sheet with slits; 8: first
melt-bonding part; 11: second melt-bonding part; 12: base sheet;
13: holding sheet; 14: receiving part; 15: holding tool; 16:
insertion part; 16a: protrusion; 17: holder part; 18: melt-bonding
line; 20: reed-shaped part; 20a: slit; 100: cleaning
member-producing device; 102a and b: first nip rolls; 104: tension
roll; 106a and b: second nip rolls; 108: air supplier; 110:
transcription roll; 112a and b: third nip rolls; 113: blade member;
114: oil solution tank; 120, 122 and 150: nonwoven fabric rolls;
121, 123 and 151: belt-shaped nonwoven fabrics; 124, 126 and 152:
dancer rolls; 128, 132, 136, 138, 140 and 156: merging parts; 130:
gather cutter; 134: second melt bonded part forming device; 154:
gather roll; 158: first melt bonded part forming device; 160:
cutting device; 181: first phototube; 182: second phototube; 183:
third phototube; 184: fourth phototube; 190: ejecting device; 201:
housing container; 202: housing container 2; 301: first
non-revolving bar; 202: second non-revolving bar; 401: fiber
bundle-holding roll.
* * * * *