U.S. patent application number 13/749723 was filed with the patent office on 2014-07-03 for method and apparatus for manufacturing 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, Yasuhiro KOYAMA.
Application Number | 20140186538 13/749723 |
Document ID | / |
Family ID | 51017487 |
Filed Date | 2014-07-03 |
United States Patent
Application |
20140186538 |
Kind Code |
A1 |
GOTO; Hiroaki ; et
al. |
July 3, 2014 |
METHOD AND APPARATUS FOR MANUFACTURING CLEANING MEMBER
Abstract
The present invention provides a novel method and apparatus for
manufacturing a cleaning member including a fiber bundle having an
oil agent uniformly attached thereto with no irregularity, wherein
a first fiber bundle fed continuously in a prescribed direction is
brought into contact with a transfer roller rotated in a direction
opposite to the feeding direction of the first fiber bundle to
transfer the oil agent applied to the surface of the transfer
roller to the first fiber bundle.
Inventors: |
GOTO; Hiroaki; (Kanonji-shi,
JP) ; KOYAMA; Yasuhiro; (Kanonji-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNICHARM CORPORATION |
Shikokuchuo-shi |
|
JP |
|
|
Assignee: |
UNICHARM CORPORATION
Shikokuchuo-shi
JP
|
Family ID: |
51017487 |
Appl. No.: |
13/749723 |
Filed: |
January 25, 2013 |
Current U.S.
Class: |
427/428.01 ;
118/244 |
Current CPC
Class: |
B08B 1/002 20130101;
A46B 9/005 20130101; D06B 1/14 20130101; D06B 1/141 20130101; A46B
7/04 20130101; A47L 13/38 20130101; D06B 1/144 20130101 |
Class at
Publication: |
427/428.01 ;
118/244 |
International
Class: |
D06B 1/14 20060101
D06B001/14 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 29, 2012 |
JP |
2012-289175 |
Claims
1. A method for manufacturing a cleaning member including a fiber
bundle having an oil agent attached thereto, the method comprising
a step of: bringing the fiber bundle continuously fed in a
prescribed direction into contact with a roller rotated in a
direction opposite to the feeding direction of the fiber bundle so
as to transfer the oil agent applied on the surface of the roller
to the fiber bundle.
2. The method according to claim 1, wherein the fiber bundle is
brought into contact with the roller while the fiber bundle is held
in a floating state.
3. The method according to claim 1, wherein the roller is a mirror
surface roller.
4. The method according to claim 1, further comprising a step of
applying the oil agent to the surface of the roller before bringing
the fiber bundle into contact with the roller.
5. The method according to claim 4, wherein the oil agent is
applied to the surface of the roller by rotating the roller with a
portion thereof being dipped in a bath containing the oil
agent.
6. The method according to claim 4, further comprising a step of
achieving a uniform thickness of the oil agent applied to the
surface of the roller before bringing the fiber bundle into contact
with the roller and after applying the oil agent to the surface of
the roller.
7. An apparatus for manufacturing a cleaning member including a
fiber bundle having an oil agent attached thereto, the apparatus
comprising: a fiber bundle feeding unit that feeds the fiber bundle
in a prescribed direction; a roller provided so as to come into
contact with the fiber bundle while being rotated in a direction
opposite to the feeding direction of the fiber bundle; and an oil
agent application unit that applies the oil agent to the surface of
the roller before the roller comes into contact with the fiber
bundle.
8. The apparatus according to claim 7, wherein any member which
presses the fiber bundle to the roller is not provided.
9. The apparatus according to claim 7, wherein the roller is a
mirror surface roller.
10. The apparatus according to claim 7, wherein the oil agent
application unit applies the oil agent to the surface of the roller
by rotating the roller with a portion thereof being dipped in a
bath containing the oil agent.
11. The apparatus according to claim 7, further comprising a blade
member which scraps off an excess of the oil agent applied to the
surface of the roller before bringing the fiber bundle into contact
with the roller and after applying the oil agent to the surface of
the roller.
12. The apparatus according to claim 7, further comprising a roll
provided at a certain clearance to the roller so as to achieve a
uniform thickness of the oil agent applied to the surface of the
roller before bringing the fiber bundle into contact with the
roller and after applying the oil agent to the surface of the
roller.
Description
TECHNICAL FIELD
[0001] The present invention relates to a method and apparatus for
manufacturing a cleaning member including a fiber bundle with an
oil agent attached thereto.
BACKGROUND ART
[0002] In a cleaning member including a fiber bundle as a
substrate, a fiber bundle having an oil agent attached thereto is
utilized in order to improve dust collecting capability of the
fiber bundle (see, for example, Patent Literature 1).
[0003] On the other hand, as a method for attaching an oil agent to
a fiber bundle, a method has been known in which a transfer roller
rolling in the same direction as the feeding direction of the fiber
bundle is brought into contact with the fiber bundle so as to
transfer an oil agent applied on the surface of the transfer roller
to the fiber bundle (see, for example, Patent Literature 2). Also,
a method has been known in which, in order to bring a fiber bundle
into adequately close contact with a transfer roller, a backup
roller provided on the side of the fiber bundle opposite to the
transfer roller is used to press the fiber bundle to the transfer
roller (see, for example, Patent Literature 1).
CITATION LIST
Patent Literature
[0004] [PTL 1] Japanese Unexamined Patent Publication No.
H05-245090 [0005] [PTL 2] Japanese Unexamined Patent Publication
No. H11-323718
SUMMARY OF INVENTION
Technical Problem
[0006] However, when the transfer roller rotating in the same
direction as the feeding direction of the fiber bundle is brought
into contact with the fiber bundle, it is difficult to attach the
oil agent uniformly to the fiber bundle with no irregularity. On
the other hand, when the backup roller is used to press the fiber
bundle to the transfer roller, the fiber bundle may be wound around
the backup roller and may give rise to trouble in feeding of the
fiber bundle.
[0007] Therefore, it is an object of the present invention to
provide a novel method and apparatus for manufacturing a cleaning
member including a fiber bundle having an oil agent uniformly
attached thereto with no irregularity.
Solution to Problem
[0008] In order to solve the above-described problem, the present
invention provides a method for manufacturing a cleaning member
including a fiber bundle having an oil agent attached thereto, the
method comprising a step of bringing the fiber bundle continuously
fed in a prescribed direction into contact with a roller rotated in
a direction opposite to the feeding direction of the fiber bundle
so as to transfer the oil agent applied on the surface of the
roller to the fiber bundle.
[0009] The present invention also provides an apparatus for
manufacturing a cleaning member including a fiber bundle having an
oil agent attached thereto, the apparatus comprising a fiber bundle
feeding unit that feeds the fiber bundle in a prescribed direction,
a roller provided so as to come into contact with the fiber bundle
while being rotated in a direction opposite to the feeding
direction of the fiber bundle, and an oil agent application unit
that applies the oil agent to the surface of the roller before the
roller comes into contact with the fiber bundle.
[0010] In the method and apparatus of the present invention, "a
direction opposite to the feeding direction of the fiber bundle"
means that the direction of the tangential velocity of the portion
of the roller in contact with the fiber bundle is opposite to the
feeding direction of the fiber bundle.
Effect of Invention
[0011] According to the present invention, it is possible to
provide a novel method and apparatus for manufacturing a cleaning
member including a fiber bundle having an oil agent uniformly
attached thereto with no irregularity.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a perspective view showing a cleaning member
manufactured according to an embodiment of the method and apparatus
of the present invention, and a holder to be fixed to the cleaning
member;
[0013] FIG. 2 is a cross-sectional view taken along the line X-X of
FIG. 1;
[0014] FIG. 3 is a plan view showing the cleaning member shown in
FIG. 1;
[0015] FIG. 4 is a schematic view useful for explaining the method
and apparatus for manufacturing the cleaning member shown in FIG.
1; and
[0016] FIG. 5 is a cross-sectional view useful for explaining
another embodiment of the method and apparatus for manufacturing
the cleaning member shown in FIG. 1.
DESCRIPTION OF EMBODIMENTS
[0017] The present invention will be described in detail below.
[0018] A method according to aspect 1A of the present invention is
a method for manufacturing a cleaning member including a fiber
bundle having an oil agent attached thereto, comprising a step of
bringing the fiber bundle continuously fed in a prescribed
direction into contact with a roller rotated in a direction
opposite to the feeding direction of the fiber bundle so as to
transfer the oil agent applied on the surface of the roller to the
fiber bundle. By using the roller rotated in a direction opposite
to the feeding direction of the fiber bundle, the oil agent is
accumulated between the fiber bundle and the roller at a position
upstream of the contact point of the fiber bundle and the roller in
the rotating direction of the roller, so that the oil agent can be
attached uniformly to the fiber bundle with no irregularity. Thus,
in accordance with the method according to aspect 1A, it is
possible to manufacture a cleaning member including a fiber bundle
having an oil agent uniformly attached thereto with no
irregularity.
[0019] In the method according to aspect 1A, the fiber bundle is
preferably brought into contact with the roller while the fiber
bundle is held in a floating state (aspect 2A). The term "floating
state" means that, when a force is exerted to the fiber bundle, the
fiber bundle is free to be moved in any direction of the exerted
force (for example, upward, downward, to the left or to the right).
For example, if, at the time of contact of the fiber bundle with
the roller, upward pressing force is exerted to the fiber bundle by
the roller, the fiber bundle is free to be moved in upward
direction, and when the force is released, it is free to be moved
downward direction. In the method according to aspect 2A, by
holding the fiber bundle in floating state and bringing the fiber
bundle into contact with the roller being rotated in the direction
opposite to the feeding direction of the fiber bundle, the oil
agent can be attached uniformly to the fiber bundle with no
irregularity, and unlike the case where a backup roller is used to
press the fiber bundle against the roller, there is no risk of the
fiber bundle being wound around the backup roller and giving rise
to trouble to smooth feeding of the fiber bundle. Thus, in
accordance with the method according to aspect 2A, it is possible
to efficiently manufacture a cleaning member including a fiber
bundle having an oil agent uniformly attached thereto with no
irregularity.
[0020] In the method according to aspect 1A or 2A, the roller is
preferably a mirror surface roller (aspect 3A). In accordance with
the method according to aspect 3A, the fiber bundle can be
prevented from being wound around the roller, so that it is
possible to efficiently manufacture a cleaning member including a
fiber bundle having an oil agent uniformly attached thereto with no
irregularity.
[0021] The method according to any one of aspects 1A to 3A
preferably further comprises a step of applying the oil agent to
the surface of the roller before bringing the fiber bundle into
contact with the roller (aspect 4A).
[0022] In the method according to aspect 4A, the oil agent is
preferably applied to the roller by rotating the roller with a
portion thereof dipped in a bath containing the oil agent (aspect
5A).
[0023] The method according to aspect 4A or 5A preferably further
comprises a step of achieving a uniform thickness of the oil agent
applied on the surface of the roller before bringing the fiber
bundle into contact with the roller and after applying the oil
agent to the surface of the roller (aspect 6A).
[0024] The method according to any one of aspects 1A to 6A may
comprise other steps. Other steps may be suitably selected in
accordance with the constructions of a cleaning member to be
manufactured. Other steps may include, for example, a step of
opening the fiber bundle, a step of forming a multilayer web by
stacking the opened fiber bundle on one or more other members (for
example, a belt-shaped non-woven fabric, etc.), a step of fixing
(for example, heat sealing, ultrasonic sealing) the fiber bundle
and other members included in the multilayer web, a step of cutting
out individual cleaning members from the multilayer web, and the
like. The method according to any one of aspects 1A to 6A may
comprises one, two or more of these steps. In this case, a step of
transferring the oil agent to the fiber bundle may be performed in
any time point as long as manufacture of a cleaning member is not
impeded. For example, when the method according to any one of
aspects 1A to 6A comprises a step of opening the fiber bundle, a
step of transferring the oil agent to the fiber bundle may be
performed during or after the step of opening the fiber bundle.
[0025] An apparatus according to aspect 1B of the present invention
is an apparatus for manufacturing a cleaning member including a
fiber bundle having an oil agent attached thereto, comprising a
fiber bundle feeding unit that feeds the fiber bundle in a
prescribed direction, a roller provided so as to come into contact
with the fiber bundle while being rotated in a direction opposite
to the feeding direction of the fiber bundle, and an oil agent
application unit that applies the oil agent to the surface of the
roller before the roller comes into contact with the fiber bundle.
By using the roller rotated in the direction opposite to the
feeding direction of the fiber bundle, the oil agent is accumulated
between the fiber bundle and the roller at a position upstream of
the contact point of the fiber bundle and the roller in the
rotating direction of the roller, so that the oil agent can be
attached uniformly to the fiber bundle with no irregularity.
Therefore, with the apparatus according to aspect 1B, it is
possible to manufacture a cleaning member including a fiber bundle
having an oil agent uniformly attached thereto with no
irregularity.
[0026] In the apparatus according to aspect 1B, preferably, any
member which presses the fiber bundle to the roller is not provided
(aspect 2B). In the apparatus according to aspect 2B, since any
member which presses the fiber bundle to the roller is not
provided, the fiber bundle held in floating state is brought into
contact with the roller rotating in the direction opposite to the
feeding direction of the fiber bundle, so that the oil agent can be
attached uniformly to the fiber bundle with no irregularity, and
unlike the case where a backup roller is used to press the fiber
bundle against the roller, there is no risk of the fiber bundle
being wound around the backup roller and giving rise to trouble to
smooth feeding of the fiber bundle. Thus, with the apparatus
according to aspect 2B, it is possible to efficiently manufacture a
cleaning member including a fiber bundle having an oil agent
uniformly attached thereto with no irregularity.
[0027] In the apparatus according to aspect 1B or 2B, the roller is
preferably a mirror surface roller (aspect 3B). With the apparatus
according to aspect 3B, it is possible to efficiently manufacture a
cleaning member including a fiber bundle having an oil agent
uniformly attached thereto with no irregularity.
[0028] In the apparatus according to any one of aspects 1B to 3B,
the oil agent application unit preferably applies the oil agent to
the surface of the roller by rotating the roller with a portion
thereof dipped in an oil agent bath (aspect 4B).
[0029] The apparatus according to any one of aspects 1B to 4B
preferably further comprises a blade member which scraps off an
excess of the oil agent applied to the surface of the roller before
bringing the fiber bundle into contact with the roller and after
applying the oil agent to the surface of the roller (aspect
5B).
[0030] The apparatus according to any one of aspects 1B to 4B
preferably further comprises a roll provided at a constant
clearance to the roller so as to achieve a uniform thickness of the
oil agent applied to the surface of the roller before bringing the
fiber bundle into contact with the roller and after applying the
oil agent to the surface of the roller (aspect 6B).
[0031] The apparatus according to any one of aspects 1B to 6B may
comprises other constructs. Other constructs can be selected
suitably in accordance with the constructions of a cleaning member
to be manufactured. Other constructs may include, for example, an
opening unit which opens the fiber bundle, a formation unit which
forms a multilayer web by stacking the opened fiber bundle on one,
two or more members (for example, a belt-shaped non-woven fabric,
etc.), a fixing unit (for example, heat sealing unit, ultrasonic
sealing unit, etc.) which fixes the fiber bundle to other members
included in the multilayer web, and a cut-out unit which cuts out
individual cleaning members from the multilayer web. The apparatus
according to aspects 1B to 6B may include one, two or more of these
constructs.
[0032] A cleaning member to be manufactured by the method and
apparatus of the present invention is not particularly limited as
long as it includes a fiber bundle having an oil agent attached
thereto. As a cleaning member to be manufactured by the method and
apparatus of the present invention, a cleaning member 1 shown in
FIGS. 1 to 3, for example, may be mentioned.
[0033] Taking the case of manufacturing the cleaning member 1 as an
example, an embodiment of the method and apparatus of the present
invention will be described below.
[0034] First, based on FIGS. 1 to 3, the cleaning member 1 will be
described.
[0035] FIG. 1 is a perspective view showing the cleaning member 1
and a holder 15 fixed to the cleaning member 1, FIG. 2 is a
cross-sectional view taken along the line X-X in FIG. 1, and FIG. 3
is a plan view showing the cleaning member 1 shown in FIG. 1. In
the description that follows, although "TOP" and "BOTTOM" in FIG. 2
may be sometimes taken as upper side and lower side, respectively,
"TOP" and "BOTTOM" in FIG. 2 are used simply for convenience of
explanation, and do not limit upper and lower directions of the
cleaning member 1.
[0036] As shown in FIGS. 1 to 3, the cleaning member 1 comprises a
brush part 2, a substrate sheet 12 stacked on the brush part 2, and
a holding sheet 13 stacked on the substrate sheet 12.
[0037] As shown in FIGS. 1 to 3, the cleaning member 1 has
receiving parts 14 formed to receive an insertion part 16 of the
holder 15 between the substrate sheet 12 and the holding sheet 13.
As shown in FIGS. 1 to 3, the cleaning member 1 has two receiving
parts 14 formed in order to permit the insertion part 16 having two
branches. Although the number of receiving parts 14 is two in the
present embodiment, the number of receiving parts 14 may be
suitably modified depending on the number of branches of the
insertion part 16. In another embodiment, the number of receiving
parts 14 may be three or more.
[0038] As shown in FIG. 2, the brush part 2 comprises four layers
of fibrous members consisting of a first fibrous member 3, a second
fibrous member 4 stacked on the lower side of the first fibrous
member 3, a third fibrous member 5 stacked on the lower side of the
second fibrous member 4, and a fourth fibrous member 6 stacked on
the lower side of the third fibrous member 5, and a sheet with
slits 7 stacked on the lower side of the four layers of the fibrous
members (on the lower side of the fourth fibrous member 6).
Although the fibrous members of the brush part 2 of the present
embodiment have four-layered structure, layered structure of the
fibrous members may be suitably modified. In another embodiment,
the layered structure of the fibrous members may be monolayered
structure, two-layered structure, or three-layered structure. In
still another embodiment, the layered structure of the fibrous
members may be a structure constructed of five or more layers.
Although the brush part 2 of the present embodiment comprises the
sheet with slits 7, the presence or absence of the sheet with slits
7 may be suitably chosen. Thus, in another embodiment, the sheet
with slits 7 may be omitted.
[0039] The first to the fourth fibrous members 3 to 6 are fiber
bundles having an oil agent attached thereto. The oil agent in the
present embodiment is a dust-collecting oil agent (such as an oil
agent containing liquid paraffin as a main component) that exhibits
promoting an effect of adsorbing dust and dirt. The amount of the
oil agent per cleaning member is usually 0.05 to 2 g/piece,
preferably 0.1 to 1 g/piece, more preferably 0.2 to 0.5 g/piece. If
the amount of the oil agent is less than 0.05 g/piece, capability
for holding dust and dirt may be lowered, and if the amount exceeds
2 g/piece, the oil agent may adhere to an object to be cleaned (for
example, furniture and the like). Components of the dust collecting
oil agent are not particularly limited, and include mineral oils,
synthetic oils, silicone oils, surface active agents and the like.
Mineral oils may be paraffinic hydrocarbons, naphthenic
hydrocarbons, aromatic hydrocarbons, etc. Synthetic oils may be,
for example, alkyl benzene oils, polyolefin oils, polyglycol oils,
etc. Silicone oils may be, for example, chain dimethyl
polysiloxane, ring dimethyl polysiloxane, methyl hydrodiene
polysiloxane, various modified silicones, etc. Surface active
agents may be, for example, cationic surface active agents such as
quaternary ammonium salt type surfactant, non-ionic surface active
agents such as polyethylene glycol type surfactants, polyalcohol
type surfactants, etc.
[0040] If the dust collecting oil agent is an oil agent having
liquid paraffin as a main component, viscosity of the oil agent is
preferably in the range of 108 to 128 mm.sup.2/S. This viscosity is
the viscosity as measured by Ubbelohde method (30.degree. C.)
carried out using an Ubbelohde viscometer (defined in JIS K
2839-1980 with coefficient determined in SIS B-0017), a thermometer
(as defined in JIS B7410-1982 for dynamic viscosity measurement)
and a thermostat (as defined in JIS K2283-1983).
[0041] The fiber bundle may be, for example, TOW, preferably opened
TOW. The term "TOW" means a bundle of a large number of filaments
as described in JIS L 0204-3:1998 3.1.24.
[0042] The fiber bundle may be a bundle of slit fibers (fibers
formed by cutting a film in elongated form and extending them),
split fibers (fibers formed by splitting an elongated film into
network segments), or the like.
[0043] As the fiber bundle, a fiber bundle composed of
thermoplastic fiber, fiber bundle containing thermoplastic fiber,
etc., may be mentioned. Raw material of the fiber forming the fiber
bundle may be, for example, polyethylene, polypropylene,
polyethylene terephthalate, nylon, rayon, etc. Type of the fiber
forming the fiber bundle may be, for example, single fiber,
composite fiber (for example, core-sheath type composite fiber,
side-by-side type composite fiber). Preferably, in view of thermal
bondability, composite fiber is core-sheath type composite fiber
with melting point of core higher than melting point of sheath.
[0044] As preferred core-sheath type composite fiber, core-sheath
type composite fiber with core composed of polypropylene or
polyethylene terephthalate and sheath composed of polyethylene may
be mentioned.
[0045] Fineness of the fiber forming the fiber bundle is preferably
1 to 50 dtex, and more preferably 2 to 10 dtex. The fiber bundle
may contain plural types of fiber having same fineness, or may
contain single or plural types of fiber having different
fineness.
[0046] In the present embodiment, each fiber composing the fiber
bundle is formed as crimped fiber. By forming each fiber as crimped
fiber, the fiber bundle can be constructed in bulky form, and can
have structure suitable for adsorbing dust and dirt in the crimped
portion. In other embodiment, each fiber composing the fiber bundle
may be formed as non-crimped fiber.
[0047] As will be described later, the sheet with slits 7 is formed
of non-woven fabric consisting of thermoplastic fibers (thermally
bondable fibers) or non-woven fabric containing thermoplastic
fibers, just like the substrate sheet 12 and the holding sheet 13,
and is formed in rectangular shape of generally same width and
generally same length as the substrate sheet 12. The sheet with
slits 7 is provided with incisions (not shown) in the shape of saw
tooth at a prescribed separation over the entire length of the
sheet with slits 7. With these incisions, reed-shaped parts having
the shape of saw tooth on both edges along the entire length at
both edges in width direction of the sheet with slits 7 are formed
(not shown).
[0048] As shown in FIGS. 1 to 3, the substrate sheet 12 and the
holding sheet 13 are stacked in this order on the upper side of the
first fibrous member 3 of the brush part 2, and the receiving part
14 which receives the insertion part 16 of the holder 15 is formed
between the substrate sheet 12 and the holding sheet 13.
[0049] As shown in FIG. 3, the substrate sheet 12 and the holding
sheet 13 have both rectangular shapes, such that both sheets 12, 13
are set so as to have same dimension in width direction (left-right
direction in FIG. 3), and dimension in length direction (up-down
direction in FIG. 3) of the substrate sheet 12 is set to be larger
than the holding sheet 13, and the holding sheet 13 is stacked on
the substrate sheet 12 such that both longitudinal ends of the
substrate sheet 12 project outward by a prescribed length from both
longitudinal ends of the holding sheet 13.
[0050] The substrate sheet 12 and the holding sheet 13 are formed
of non-woven fabric composed of thermoplastic fiber (heat adhesive
fiber) or non-woven fabric containing thermoplastic fiber. As the
thermoplastic fiber, for example, polyethylene fiber, polyethylene
terephthalate fiber, composite fiber composed of polyethylene fiber
and polyethylene terephthalate fiber, composite fiber composed of
polyethylene fiber and polypropylene fiber, and core-sheath type
composite fiber with the core composed of polyethylene
terephthalate and the sheath composed of polyethylene, for example,
may be mentioned. Type of the non-woven fabric may be, for example,
thermal bond non-woven fabric, spunbonded non-woven fabric,
spunlace non-woven fabric, etc.
[0051] In other embodiment, the substrate sheet and the holding
sheet are formed of thermoplastic resin film, for example,
polyethylene film, polypropylene film. In still other embodiment,
the substrate sheet and the holding sheet are formed of laminate
sheet of non-woven fabric and resin film.
[0052] The substrate sheet 12 and the holding sheet 13 are melt
bonded in one unit to all layers of the brush part 2 (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)
by a first melt bonded part forming device 158 to be described
later, and as shown in FIGS. 1 to 3, in the cleaning member 1, a
first melt bonded part 8 extending in longitudinal direction is
formed in center portion in width direction. Further, the substrate
sheet 12 and the holding sheet 13 are melt bonded on both sides (on
the left and the right) of the first melt bonded part 8 to one
layer (the first fibrous member 3) by a second melt bonded part
forming device 134, and two second melt bonded parts 11 are formed
in longitudinal direction in the cleaning member 1. Two second melt
bonded parts 11 are intermittently formed, respectively. By fusion
of the first fibrous member 3 to the substrate sheet 12 and the
holding sheet 13, the first fibrous member 3 follows the movement
of these sheets 12, 13, so that the brush part 2 is more easily
expanded at the time of usage, and cleaning efficiency can be
thereby improved.
[0053] The substrate sheet 12 and the holding sheet 13 are melt
bonded to all layers of the brush part 2 (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) at the first
melt bonded part 8, and are further melt bonded to the first
fibrous member 3 of the brush part 2 at the two second melt bonded
parts 11. Thus, a pair of receiving parts 14 is formed between the
substrate sheet 12 and the holding sheet 13 as a bag-shaped space
that is delimited by the first melt bonded part 8 and the two
second melt bonded parts 11, extends in longitudinal direction of
the substrate sheet 12 and the holding sheet 13 and opens at both
longitudinal ends, so that the insertion part 16 of the holder 15
can be inserted in the receiving part 14.
[0054] The substrate sheet 12 and the holding sheet 13 are melt
bonded to the first fibrous member 3 of the brush part 2 at center
portion thereof by the second melt bonded part forming device 134
to be described later, and as shown in FIG. 3, a pair of melt
bonding lines 18 is formed in the cleaning member 1 at a prescribed
separation in width direction of the substrate sheet 12 and the
holding sheet 13, and the first melt bonded part 8 is formed
between the pair of melt bonding lines 18. The pair of melt bonding
lines 18 is a mark for controlling the position of the first melt
bonded part 8 in manufacture stage, and by controlling whether or
not the first melt bonded part 8 is situated between the pair of
heat melt bonding lines 18, selection between defective and
non-defective product can be carried out.
[0055] As shown in FIGS. 1 to 3, two second melt bonded parts 11
are provided intermittently in longitudinal direction of the
substrate sheet 12 and the holding sheet 13, and by engaging
circular arc-shaped protrusion 16a of each insertion part 16 of the
holder 15 with the non-fusion portion of the two second melt bonded
parts 11, each insertion part 16 of the holder 15 is prevented from
slipping out of each receiving part 14.
[0056] As shown in FIG. 1, incisions 20a in the shape of saw tooth
are provided at a prescribed separation along longitudinal
direction on both edge portions (portions outside of two second
melt bonded parts 11) in width direction of the substrate sheet 12
and the holding sheet 13, and with these incisions 20a, plural
reed-shaped parts 20 with both edges in the shape of saw tooth are
provided. In other embodiment, incisions 20a in the shape of saw
tooth are provided in the substrate sheet 12 and the holding sheet
13, and therefore, no reed-shaped part 20 is formed.
[0057] As shown in FIG. 1, the holder 15 has a pair of insertion
parts 16 in the shape of rectangular plate arranged in parallel to
each other, a pair of circular arc-shaped protrusions 16a
projecting from outer side of both longitudinal ends of each
insertion part 16, and a holder part 17 integrally provided on one
end of the insertion part 16, and is formed of, for example,
plastic and the like.
[0058] By inserting both insertion parts 16 of the holder 15 into
both receiving parts 14 of the cleaning member 1 and engaging the
protrusions 16a with the non-fusion portion of the two second melt
bonded parts 11, the cleaning member 1 is mounted to the holder 15.
By holding the holder part 17 of the holder 15 and bringing the
brush part 2 into contact with the point to be cleaned and moving
it in desired direction, dust and dirt at the point to be cleaned
are captured by the brush part 2 and the point to be cleaned is
cleaned.
[0059] Next, an embodiment of the method and apparatus for
manufacturing a cleaning member 1 will be described with reference
to FIG. 4.
[0060] FIG. 4 is a schematic view useful for explaining the method
and apparatus for manufacturing a cleaning member 1, and in the
present embodiment, the apparatus 100 shown in FIG. 4 is used to
carry out the method for manufacturing the cleaning member 1 and
the cleaning member 1 is manufactured.
[0061] In the present embodiment, the manufacturing method for
manufacturing the cleaning member 1 comprises the following steps 1
and 2.
[Step 1] Step of manufacturing a fiber bundle having an oil agent
attached thereto. [Step 2] Step of using the fiber bundle having
the oil agent attached thereto to manufacture a continuous body of
cleaning members and cutting out the cleaning member 1 from the
continuous body of cleaning members.
<Step 1>
[0062] Step 1 will be described below
[0063] In the present embodiment, step 1 includes the following
steps 1a and 1b
[Step 1a] Step of opening a first fiber bundle F1 to a fourth fiber
bundle F4. [Step 1b] Step of applying an oil agent to the first
fiber bundle F1 to the fourth fiber bundle F4.
[0064] In the present embodiment, although step 1 includes step 1a,
presence or absence of step 1a may be suitably selected in
accordance with type of the fiber bundle used. In other embodiment,
step 1a may be omitted. For example, if the fiber bundle is
composed of non-crimped fiber, step 1a can be omitted.
[Step 1a]
[0065] Step 1a will be described below taking a step of opening the
first fiber bundle F1 as an example. Steps of opening other fiber
bundles (the second fiber bundle F2 to the fourth fiber bundle F4)
are carried out in the same way.
[0066] The first fiber bundle F1 composed of crimped fibers is
drawn out continuously from a storage container (not shown), and is
fed to a first nip rollers 102a, 102b rotating at a constant
peripheral velocity V1. The first fiber bundle F1 passing past the
first nip roller 102a, 102b is, after passing plural tension
rollers 104, fed to a second nip rollers 106a, 106b rotating at
peripheral velocity V2.
[0067] The peripheral velocity V2 of the second nip rollers 106a,
106b is higher than the peripheral velocity V1 of the first nip
rollers 102a, 102b. Owing to this difference between the peripheral
velocities, tension is imparted to the first fiber bundle F1
between the first nip rollers 102a, 102b and the second nip rollers
106a, 106b, and as a result, the first fiber bundle F1 is
opened.
[0068] Each tension roller 104 is formed of, for example, solid
steel, and its mass is adjusted such that significant force is
required for rotation. Therefore, when the first fiber bundle F1
advances from the first nip rollers 102a, 102b to the second nip
rollers 106a, 106b while rotating each tension roller 104, speed of
movement of the first fiber bundle F1 is not increased
suddenly.
[0069] Each of the tension rollers 104 is disposed such that, in
order to open the first fiber bundle F1 slowly, the distance from
the first nip rollers 102a, 102b to the second nip rollers 106a,
106b is sufficiently long.
[0070] After passing the second nip rollers 106a, 106b, the first
fiber bundle F1 passes an air supplying device 108, and is fed to
the third nip rollers 112a, 112b rotating at peripheral velocity
V3. The peripheral velocity V3 of the third nip rollers 112a, 112b
is lower than the peripheral velocity V2 of the second nip rollers
106a, 106b. Owing to this difference between the peripheral
velocities, tension of the first fiber bundle F1 is relaxed between
the second nip rollers 106a, 106b and the third nip rollers 112a,
112b, and as a result, the first fiber bundle F1 is opened further
and the width of the first fiber bundle F1 is increased.
[0071] While the first fiber bundle F1 is fed from the second nip
rollers 106a, 106b to the third nip rollers 112a, 112b, air is
blown to the first fiber bundle F1 by the air supplying device 108,
and as a result, the first fiber bundle F1 is further opened.
[0072] In the present embodiment, opening of the first fiber bundle
F1 is promoted by imparting and relaxing of tension and blow of
air. But, a method for opening the fiber bundle may be suitably
modified. In other embodiment, only one of imparting and relaxing
of tension and blow of air is used. In still other embodiment,
other methods of opening the fiber bundle are used in addition to
imparting and relaxing of tension and blow of air. Although, in the
present embodiment, the first to the third nip rollers are used for
imparting and relaxing tension, the number of nip rollers may be
suitably chosen. In other embodiment, in addition to the first to
the third nip rollers, other nip rollers may be used.
[Step 1b]
[0073] Step 1b will be described below taking a step of applying an
oil agent to the first fiber bundle F1 as an example. Steps of
applying an oil agent to other fiber bundles (the second fiber
bundle F2 to the fourth fiber bundle F4) are carried out in the
same way.
[0074] Step 1b is carried out using a transfer roller 110 provided
between the second nip rollers 106a, 106b and the third nip rollers
112a, 112b. Thus, in the present embodiment, step 1b is carried out
between the second nip rollers 106a, 106b and the third nip rollers
112a, 112b, that is, during step 1a. However, time for carrying out
step 1b may be suitably modified. In other embodiment, step 1b is
carried out after step 1a.
[0075] The transfer roller 110 is a roller generally used as a roll
coater, and is not particularly limited as long as a film of an oil
agent can be formed on the roller surface, and is preferably a
mirror surface roller. If the transfer roller 110 is a mirror
surface roller, the first fiber bundle F1 is prevented from winding
around the transfer roller 110, and a cleaning member comprising a
fiber bundle having an oil agent uniformly attached thereto can be
manufactured efficiently. Rollers that can be used as the transfer
roller 110 include, in addition to a mirror surface roller, a
roller with surface formed of porous ceramics (for example, a metal
roller coated or vapor-deposited with porous ceramics), a roller
with metal plating and satin finish on the surface, for
example.
[0076] As the diameter of the transfer roller 110 is increased, the
area of contact with the first fiber bundle F1 is increased so that
uniformity of the transferred oil agent is improved. If, however,
the diameter becomes too large, the feeding of the first fiber
bundle F1 may be impeded, and the size of the equipment also needs
to be increased. On the other hand, as the diameter of the transfer
roller 110 is decreased, the area of contact with the first fiber
bundle F1 is also decreased and the feeding of the first fiber
bundle F1 is not impeded so that the size of the equipment can be
reduced. If, however, the diameter becomes too small, uniformity of
the transferred oil agent is lowered. Therefore, the diameter of
the transfer roller 110 is suitably adjusted taking account of
these points. The width (length in axial direction) of the transfer
roller 110 is adjusted so as to be larger than the width of the
first fiber bundle F1 between the second nip rollers 106a, 106b and
the third nip rollers 112a, 112b.
[0077] The rotational speed of the transfer roller 110 is suitably
adjusted with the feeding velocity of the first fiber bundle F1 and
the diameter of the transfer roller 110 taken into account such
that a film of oil agents is formed on the surface of the roller.
For example, if the feeding velocity of the first fiber bundle F1
is 5 to 100 m/min, the rotational speed of the transfer roller 110
may be adjusted to 5 to 0.5 rpm. In a preferred embodiment, the
feeding velocity of the first fiber bundle F1 is 23.1 m/min, the
diameter of the transfer roller 110 is 214 mm, and the rotational
speed of the transfer roller 110 is 1.375 rpm.
[0078] The transfer roller 110 is provided such that, with a
driving system, it is brought into contact with the first fiber
bundle F1 while being rotated in a direction opposite to the
feeding direction D1 of the first fiber bundle F1. The expression
"a direction opposite to the feeding direction D1 of the first
fiber bundle F1" means that the direction of the tangential
velocity of the portion of the transfer roller 110 contacting with
the first fiber bundle F1 is opposite to the feeding direction D1
of the first fiber bundle F1.
[0079] As shown in FIG. 4, an oil agent bath 114 is provided at a
position upstream of the contact point of the first fiber bundle F1
and the transfer roller 110 in rotating direction of the transfer
roller 110. With such construction, before a prescribed portion of
the surface of the transfer roller 110 comes into contact with the
first fiber bundle F1, an oil agent is applied to the prescribed
portion.
[0080] An oil agent is contained in the oil agent bath 114. In the
present embodiment, the oil agent contained in the oil agent bath
114 is a dust collecting oil agent (for example, an oil agent
including liquid paraffin as a main component).
[0081] The amount of the oil agent contained in the oil agent bath
114 and the position of the rotational axis of the transfer roller
110 is adjusted such that a portion of the transfer roller is
dipped in the oil agent contained in the oil agent bath 114. The
transfer roller 110 is rotated with a portion thereof dipped in the
oil agent bath 114 so that the oil agent is continuously applied to
the surface of the transfer roller 110. The amount of the applied
oil agent is adjusted such that the amount of the oil agent per one
cleaning member is usually 0.05 to 2 g/piece, preferably 0.1 to 1
g/piece, and more preferably 0.2 to 0.5 g/piece. If the dust
collecting oil agent is an oil agent having liquid paraffin as a
main component, the viscosity of the oil agent is preferably 108 to
128 mm.sup.2/S. This viscosity is the viscosity as measured by
Ubbelohde method (30.degree. C.) carried out using an Ubbelohde
viscometer (defined in JIS K 2839-1980 with coefficient determined
in SIS B-0017), a thermometer (defined in JIS B7410-1982 for
dynamic viscosity measurement) and a thermostat (defined in JIS
K2283-1983).
[0082] A blade member 113 is provided at a position upstream of the
contact point of the first fiber bundle F1 and the transfer roller
110 in rotating direction of the transfer roller 110 and downstream
of the position of the oil agent bath 114 in rotating direction of
the transfer roller 110 in order to scrape off an excess of the oil
agent applied to the surface of the transfer roller 110. With this
construction, before the prescribed portion of the surface of the
transfer roller 110 comes into contact with the first fiber bundle
F1 and after the oil agent is applied to the prescribed portion, an
excess of the oil agent applied to the prescribed portion is
scraped off. By scraping off an excess of the oil agent applied to
the surface of the transfer roller 110, the blade member 113
achieves a uniform thickness of the oil agent applied to the
surface of the transfer roller (so as to form a thin film).
[0083] In the present embodiment, the blade member 113 is used to
achieve a uniform thickness of the oil agent applied to the surface
of the transfer roller 110 (so as to form a thin film), the same
effect can be obtained by using other member. In other embodiment,
a roll 115 may be disposed, as shown in FIG. 5, at a position
upstream of the contact point of the first fiber bundle F1 and the
transfer roller 110 in rotating direction of the transfer roller
110 and downstream of the position of the oil agent bath 114 in
rotating direction of the transfer roller 110 in order to scrape
off an excess of the oil agent applied to the surface of the
transfer roller 110 in a constant clearance (separation) to the
transfer roller 110. In this embodiment, as shown in FIG. 5, by
rotating the transfer roller 110 and the roll 115 in opposite
direction at a position for achieving a uniform thickness of the
oil agent applied to the surface of the transfer roller 110 (so as
to form a thin film), a uniform thickness of the oil agent 116
applied to the surface of the transfer roller 110 can be
effectively achieved (so as to form a thin film).
[0084] When the first fiber bundle F1 continuously fed by the
second nip rollers 106a, 106b and the third nip rollers 112a, 112b
in the prescribed direction D1 comes into contact with the transfer
roller 110 rotated in the direction opposite to the feeding
direction D1 of the first fiber bundle F1, the oil agent applied on
the surface of the surface of the transfer roller 110 is
transferred to the first fiber bundle F1. In this manner, the first
fiber bundle having the oil agent attached thereto is manufactured.
The transfer roller 110 is rotated with a portion thereof dipped in
the oil agent bath and with another portion thereof in contact with
the first fiber bundle F1, so that the oil agent is continuously
transferred to the first fiber bundle F1 that is continuously fed
in the prescribed direction D1. By using the transfer roller 110
rotated in the direction opposite to the feeding direction D1 of
the first fiber bundle F1, the oil agent is accumulated between the
first fiber bundle F1 and the transfer roller 110 at a position
upstream of the contact point of the transfer roller 110 with the
first fiber bundle F1 in the rotating direction of the transfer
roller 110, so that the oil agent can be uniformly attached to the
first fiber bundle F1 with no irregularity.
[0085] Between the second nip rollers 106a, 106b and the third nip
rollers 112a, 112b, the first fiber bundle F1 is held in a floating
state, and the first fiber bundle F1 comes into contact with the
transfer roller 110 in floating state. The term "floating state"
means that, when a force is exerted to the first fiber bundle F1,
the first fiber bundle F1 is free to move in the direction of the
exerted force. For example, if, when the first fiber bundle F1
comes into contact with the transfer roller 110, a force is exerted
by the transfer roller 110 in upward direction in FIG. 4, the first
fiber bundle F1 is free to be moved in upward direction in FIG. 4,
and when the force is released, it is free to move in downward
direction in FIG. 4.
[0086] In order to ensure the floating state of the first fiber
bundle F1, no member which presses the first fiber bundle F1 to the
transfer roller 110 is provided at the position of contact of the
first fiber bundle F1 with the transfer roller 110 on the side of
the first fiber bundle F1 opposite to the transfer roller 110.
[0087] By holding the first fiber bundle F1 in floating state and
bringing it into contact with the transfer roller 110 rotated in
the direction opposite to the feeding direction D1 of the first
fiber bundle F1, the oil agent can be uniformly attached to the
first fiber bundle F1 with no irregularity, and unlike the case
where a backup roller is used to press the first fiber bundle F1
against the transfer roller 110, there is no risk of the first
fiber bundle F1 being wound around the backup roller and impeding
transport of the first fiber bundle F1. Therefore, with the present
embodiment, a cleaning member comprising a fiber bundle having an
oil agent uniformly attached thereto with no irregularity can be
efficiently manufactured.
[0088] After being processed in step 1, the first fiber bundle F1
proceeds to the confluence point 132. Similarly, after being
processed in step 1, the second fiber bundle F2 to the fourth fiber
bundle F4 proceed to the confluence points 136, 138, 140,
respectively.
<Step 2>
[0089] Step 2 will be described below.
[0090] In the present embodiment, step 2 includes following steps
2a to 2c.
[Step 2a] After being processed in step 1, the fiber bundle is
stacked to other member (in the present embodiment, belt-shaped
non-woven fabric) to form multilayer web. [Step 2b] Fixing the
fiber bundle to other member included in the multilayer web. [Step
2c] Cutting out individual cleaning members from the multilayer
web.
[Step 2a]
[0091] Step 2a will be described below.
[0092] In the present embodiment, other members to be stacked to
the fiber bundle after being processed in step 1 are belt-shaped
non-woven fabrics 121, 123, 151. In other embodiment, one or two of
these non-woven fabrics are stacked to the fiber bundle after being
processed in step 1. In still other embodiment, in addition to
these non-woven fabrics, other non-woven fabric is stacked to the
fiber bundle that has been processed in step 1. In any of these
embodiments, although the order of superposition is not
particularly limited, a non-woven fabric is preferably stacked so
as to be situated at the outermost position.
[0093] The non-woven fabrics 121, 123 correspond respectively to
the substrate sheet 12 and to the holding sheet 13. The non-woven
fabric 121 is continuously rolled out from the non-woven fabric
roll 120 and includes plural rollers disposed in two rows, upper
rollers and lower rollers, and is intermittently conveyed by the
roll situated in lower row passing the dancer roller 124 swinging
up and down. Similarly, the non-woven fabric 123 is continuously
rolled out from the non-woven fabric roll 122 and includes plural
rollers disposed in two rows, upper rollers and lower rollers, and
is intermittently conveyed by the roll situated in lower row
passing the dancer roller 126 swinging up and down. The expression
"intermittently conveyed" means that each of the non-woven fabrics
121, 123 is conveyed such that it advances for certain distance
(for example, about the length in width direction of a cleaning
member 1) in the feeding direction and then conveyance is stopped
for certain time period, and this cycle is repeated. By conveying
the non-woven fabrics 121, 123 intermittently in this manner, time
required for fusion of the constituents of the multilayer web can
be ensured, as will be described later.
[0094] The non-woven fabrics 121, 123 join at the confluence point
128 to form multilayer web S1, and the multilayer web S1 passes
through a gather cutter 130 having saw tooth-shaped blade (not
shown) formed intermittently in circumferential direction on its
surface. With this cutter, incisions corresponding to the incisions
20a (see FIG. 1) of the substrate sheet 12 and the holding sheet 13
are formed.
[0095] The multilayer web S1 joins at the confluence point 132 to
the first fiber bundle F1 that has been processed in step 1, and
the first fiber bundle F1 is stacked onto the multilayer web S1 to
form a multilayer web S2. At this time, the construction is such
that the first fiber bundle F1 can slacken to some extent between
the third nip rollers 112a, 112b and the confluence point 132, and
with such construction, same effect as provision of a dancer roller
between them can be obtained.
[0096] The multilayer web S2 successively joins at confluence
points 136, 138, 140 to the second fiber bundle F2 to the fourth
fiber bundle F4 that have been processed in step 1, and the second
fiber bundle F2 to the fourth fiber bundle F4 are successively
stacked onto the multilayer web S2 to form a multilayer web S3.
[0097] The non-woven fabric 151 corresponds to the sheet with slits
7. The non-woven fabric 151 is rolled out continuously from a
non-woven fabric roll 150, and by passing through a dancer roller
152, is conveyed intermittently and passes through a gather roller
154. The gather roller 154 has a saw tooth-shaped blade (not shown)
formed continuously in circumferential direction on the surface,
and with this roller, saw tooth-shaped incision (not shown) is
formed in the non-woven fabric that has passed the gather roller
154.
[0098] The non-woven fabric 151 joins at the confluence point 156
to the multilayer web S3, and the non-woven fabric 151 is stacked
on the multilayer web S3 to form a multilayer web S4.
[Step 2b]
[0099] Step 2b will be described below.
[0100] Before joining to the second fiber bundle F2 to the fourth
fiber bundle F4, the multilayer web S2 passes the second melt
bonded part forming device 134. The second melt bonded part forming
device 134 fuses the non-woven fabrics 121, 123 and the first fiber
bundle F1 included in the multilayer web S2 to form two second melt
bonded parts 11 (see FIG. 3). Thus, the multilayer web S2 is fused
through thickness direction. In the present embodiment, a heat
sealing device is used as the second melt bonded part forming
device 134. However, the second melt bonded part forming device may
be suitably changed. In other embodiment, an ultrasonic sealing
device may be used.
[0101] The multilayer web S4 passes the first melt bonded part
forming device 158. The first melt bonded part forming device 158
fuses the entire multilayer web S4 and form the first melt bonded
part 8 (see FIG. 3, etc.) in the multilayer web S4. With this
fusion, the multilayer web S4 is fused through its thickness
direction. Although, in the present embodiment, a heat sealing
device is used as the first melt bonded part forming device 154,
the melt bonded part forming device may be suitably changed. In
other embodiment, an ultrasonic sealing device may be used.
[Step 2c]
[0102] Step 2c will be described below.
[0103] The multilayer web S4 passing the first melt bonded part
forming device 158 is cut in a cutter unit 160 and individual
cleaning members 1 are cut out.
[0104] The cleaning member 1 manufactured in the present embodiment
includes a sheet with slits 7. However, the sheet with slits 7 is
not included in the cleaning member manufactured in other
embodiment. Also, in the cleaning member 1 manufactured in the
present embodiment, the counter-insertion unit 14 is situated on
the surface of the cleaning member 1. However, in the cleaning
member manufactured in other embodiment, by changing the order of
superimposition of the substrate sheet 12 and the holding sheet 13
and the fibrous members 3 to 6, the counter-insertion unit 14 is
disposed between any of adjoining fibrous members 3 to 6. With such
construction, both faces of the cleaning member 1 can be used in
cleaning. In this case, in order to facilitate insertion of the
insertion part 16 into the receiving part 14, dimension in
longitudinal direction (up-down direction in FIG. 3) of the
substrate sheet 12 and the holding sheet 13 is preferably larger
than that of the fibrous members 3 to 6, and this dimension can be
arbitrarily chosen. Also in this case, the sheet with slits 7 may
or may not be used, and the sheets with slits 7 may be disposed on
both face of the cleaning member 1.
[0105] The cleaning member illustrated in FIG. 1 to FIG. 3 is an
example of the cleaning members which can be produced using the
method of producing a cleaning member and the system of producing a
cleaning member according to the present disclosure. The method of
producing a cleaning member and the system of producing a cleaning
member according to the present disclosure can be used to produce a
cleaning member as described in, for example, Japanese Unexamined
Patent Publication No. 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, 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.
[0106] The method of producing a cleaning member and the system of
producing a cleaning member according to the present disclosure 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.
[0107] The present application claims the benefit of the following
patent applications, the entire disclosures of which are
incorporated herein by reference:
(1) JP Patent Application No. 2012-289181 filed on Dec. 29, 2012,
and US patent application claiming priority thereof, (2) JP Patent
Application No. 2012-289182 filed on Dec. 29, 2012, and US patent
application claiming priority thereof, (3) JP Patent Application
No. 2012-289174 filed on Dec. 29, 2012, and US patent application
claiming priority thereof, (4) JP Patent Application No.
2012-289189 filed on Dec. 29, 2012, and US patent application
claiming priority thereof, (5) JP Patent Application No.
2012-289175 filed on Dec. 29, 2012, (6) JP Patent Application No.
2012-289188 filed on Dec. 29, 2012, and US patent application
claiming priority thereof, (7) JP Patent Application No.
2012-289179 filed on Dec. 29, 2012, and US patent application
claiming priority thereof, (8) JP Patent Application No.
2012-289177 filed on Dec. 29, 2012, and US patent application
claiming priority thereof, (9) JP Patent Application No.
2012-289184 filed on Dec. 29, 2012, and US patent application
claiming priority thereof, (10) JP Patent Application No.
2012-289178 filed on Dec. 29, 2012, and US patent application
claiming priority thereof, (11) JP Patent Application No.
2012-289176 filed on Dec. 29, 2012, and US patent application
claiming priority thereof, (12) JP Patent Application No.
2013-002855 filed on Jan. 10, 2013, and US patent application
claiming priority thereof, as well as (13) JP Patent Application
No. 2013-002857 filed on Jan. 10, 2013, and US patent application
claiming priority thereof.
REFERENCE SIGNS LIST
[0108] 1--cleaning member, 2--brush part, 3--first fibrous member,
4--second fibrous member, 5--third fibrous member, 6--fourth
fibrous member, 7--sheet with slits, 8--first melt bonded part,
11--second melt bonded part, 12--substrate sheet, 13--holding
sheet, receiving part, 15--holder, 16--insertion part,
16a--protrusion, 17--holder part, 18--melt bonding line, 20--reed
shaped part, 20a--incision, 100--apparatus for manufacturing
cleaning member, 102a, b--first nip roller, 104--tension roller,
106a, b--second nip roller, 108--air supplying device,
110--transfer roller, 112a, b--third nip roller, 113--blade member,
114--oil agent bath, 115--roll, 116--oil agent, 120, 122,
150--non-woven fabric roll, 121, 123, 151--belt-shaped non-woven
fabric, 124, 126, 152--dancer roller, 128, 132, 136, 138, 140,
156--confluence point, 130--gather cutter, 134--second melt bonded
part forming device, 154--gather roll, 158--first melt bonded part
forming device, 160--cutter unit
* * * * *