Functional sheet and method for producing the same, and functional sheet production apparatus

Abstract

To provide a functional sheet containing multiple kinds of functional materials and allowing the respective functional materials to exhibit their functions uniformly.SOLUTION: In a breathable functional sheet 100 in which a functional material layer 130 is sandwiched between a front-side base sheet 110 and a rear-side base sheet 120, the functional material layer 130 has a laminated structure including a first functional material layer 130a in which powder-granular first functional materials 131a are laid, and a second functional material layer 130b in which powder-granular second functional materials 131b of a type different from the first functional materials 131a are laid.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a breathable functional sheet having a granular functional material sandwiched between a front substrate sheet and a back substrate sheet, a method for manufacturing the same, and a functional sheet manufacturing apparatus capable of manufacturing the functional sheet. [Background technology]

[0002] An adsorption filter (functional sheet) for adsorbing and removing substances is formed by bonding powdered activated carbon (functional material) to a nonwoven fabric (base sheet). A known method for manufacturing this type of filter is the "sintering method." As shown in FIG. 5 , in the sintering method, a mixture of activated carbon 930 and a heat-melting adhesive 940 is spread over one nonwoven fabric 920, which is then heated in a heating furnace 99 to melt the adhesive 940. Then, another nonwoven fabric 910 is placed over the activated carbon 930 and the adhesive 940, and pressure rollers 91 and 92 are used to pressurize and integrate the nonwoven fabrics 910 and 920, thereby producing a functional sheet 900 (see, for example, paragraphs 0051 to 0053 and 0055 to 0063 of Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2019-069405 Summary of the Invention [Problem to be solved by the invention]

[0004] In the above-mentioned sintering method, a mixture of multiple types of activated carbon (functional material) may be used as the activated carbon 930 (FIG. 5). That is, for example, a base-adsorbing activated carbon capable of adsorbing basic gases such as ammonia, an acid-adsorbing activated carbon capable of adsorbing acidic gases such as sulfur dioxide, and a heat-melting adhesive may be mixed and then spread on a nonwoven fabric 920 to produce a functional sheet 900. It was believed that this functional sheet 900 could adsorb both acidic gases and basic gases with a single functional sheet.

[0005] However, in this case, it may be difficult to uniformly distribute each of the multiple types of functional materials on the nonwoven fabric 920. This may result in unevenness in the adsorption function in the surface direction of the functional sheet 900, and depending on which part of the functional sheet 900 the gas to be treated passes through, there is a risk that the desired adsorption function may not be obtained.

[0006] The present invention has been made to solve the above-mentioned problems, and provides a functional sheet that contains multiple types of functional materials and that allows the functions of each functional material to be exhibited evenly. It is also an object of the present invention to provide a method for manufacturing this functional sheet and a functional sheet manufacturing apparatus that can manufacture this functional sheet. [Means for solving the problem]

[0007] The above issues are: A breathable functional sheet in which a functional material layer is sandwiched between a front substrate sheet and a back substrate sheet, The functional material layer is a first functional material layer in which granular first functional materials are spread; A second functional material layer in which a different type of powder-like second functional material from the first functional material is spread out. has a laminated structure A functional sheet characterized by This is solved by providing

[0008] In this functional sheet, a first functional material and a second functional material of a type different from the first functional material are laminated in layers, as shown in Figures 1 and 2. This makes it difficult for unevenness in function to occur in the surface direction of the functional sheet, and makes it easier for the gas to be treated to obtain the desired function no matter where it passes through the functional sheet.

[0009] The terms "front" and "back" in "front-side substrate sheet" and "back-side substrate sheet" simply refer to the side that will be the upper side when manufacturing the functional sheet, which will be described in detail later, as "front" and the side that will be the lower side as "back." Therefore, these terms do not limit the orientation in which the functional sheet is used.

[0010] In the above-mentioned functional sheet, it is preferable to bond the first functional materials together and the second functional materials together with an adhesive to prevent the first functional materials and the second functional materials from falling off. The functional materials (first functional materials and second functional materials) can also be bonded together using the sintering method described above (FIG. 5), in which a heat-melting adhesive 940 is mixed with the functional material 930 in advance, and the mixture is then spread on the base sheet 920 and heated. However, in this case, as shown in FIG. 6, the gaps between the powder-like functional material 930 may be filled with the adhesive 940, potentially reducing the breathability of the functional sheet.

[0011] For this reason, in the above-mentioned functional sheet, it is preferable that the first functional material layer comprises a thread-like adhesive that is entangled with the first functional material to connect the first functional materials together, and the second functional material layer comprises a thread-like adhesive that is entangled with the second functional material to connect the second functional materials together. As a result, as shown in Figures 1 and 2 below, the powder-like first functional materials 131a and the second functional materials 131b can be connected to each other by entangled thread-like (mesh-like) adhesives 132a and 132b, respectively, and the first functional materials 131a and the second functional materials 131b can be made less likely to fall off the functional sheet 100 while maintaining high breathability of the functional sheet 100.

[0012] In this case, it is also preferable that the functional material layer and the front substrate sheet, and the functional material layer and the back substrate sheet are bonded together with a thread-like adhesive, which makes it easier to improve the breathability of the functional sheet.

[0013] However, when using a conventional sintering method (Figure 5) to produce a functional sheet in which a first functional material and a second functional material are laminated as separate layers, it is necessary to sandwich a sheet-like member (e.g., a breathable sheet such as a nonwoven fabric, knitted fabric, or woven fabric) between the first and second functional material layers. This is because, in the sintering method, a mixture of the functional material and adhesive is dropped onto a substrate sheet and then heated to melt the adhesive. Therefore, if a mixture of the first functional material and adhesive is dropped onto a substrate sheet and a mixture of the second functional material and adhesive is dropped on top of it (without sandwiching a sheet-like member), the second functional material or adhesive may fall into the gaps between the first functional material layers, resulting in uneven thickness of the second functional material layer or insufficient adhesion of the second functional material, making it prone to falling off. However, interposing a sheet-like member between the first and second functional material layers may make it difficult to improve the breathability of the functional sheet.

[0014] In this regard, in the above-mentioned functional sheet, when the first functional materials and the second functional materials are connected to each other with a thread-like adhesive, the second functional material and the adhesive are less likely to fall into the gaps between the first functional materials, so that a sheet-like member can be avoided between the first functional material layer and the second functional material layer, which makes it easier to improve the breathability of the functional sheet.

[0015] In the above-mentioned functional sheet, different types of functional materials are used as the first functional material and the second functional material. For example, the first functional material and the second functional material may both have an adsorption function, and the substance to be adsorbed by the first functional material may not be the same as the substance to be adsorbed by the second functional material.

[0016] The above functional sheet is A functional sheet manufacturing apparatus for manufacturing a breathable functional sheet in which a functional material layer is sandwiched between a front-side substrate sheet and a back-side substrate sheet, a base sheet transport means for transporting the back side base sheet; a functional material layer forming means for forming a functional material layer on the back substrate sheet; a substrate sheet integration means for stacking the front-side substrate sheet on the upper side of the functional material layer to integrate the back-side substrate sheet, the functional material layer, and the front-side substrate sheet; Equipped with The functional material layer forming means is a first functional material hopper for dropping a powdery first functional material onto the upper side of the back-side base sheet being transferred by the base sheet transfer means, thereby forming a first functional material layer in which the first functional material is spread over; a second functional material hopper for dropping a powdery second functional material onto the upper side of the first functional material layer to form a second functional material layer in which the second functional material is spread over the first functional material layer in a laminated state; A functional sheet manufacturing apparatus comprising: It can be produced using

[0017] The term "above" in the expression "overlaying the front-side substrate sheet on top of the second functional material layer" simply means "above." Therefore, "overlaying the front-side substrate sheet on top of the second functional material layer" includes both cases where the front-side substrate sheet is directly overlaid on the second functional material layer and cases where the front-side substrate sheet is overlaid on one or more other layers laminated on the second functional material layer. The same applies to the term "above" in "dropping the powdery first functional material on top of the back-side substrate sheet" and "dropping the powdery second functional material on top of the first functional material layer." [Effects of the Invention]

[0018] As described above, the present invention makes it possible to provide a functional sheet that contains multiple types of functional materials and that allows the functions of each functional material to be exhibited evenly. It also makes it possible to provide a method for manufacturing this functional sheet and a functional sheet manufacturing apparatus that can manufacture this functional sheet. [Brief explanation of the drawings]

[0019] [Figure 1] 1 is a cross-sectional view schematically showing a functional sheet of the present embodiment cut along a plane parallel to the thickness direction. [Figure 2] 1 is a photograph showing a cross section of a functional sheet of the present embodiment cut along a plane parallel to the thickness direction. [Figure 3] 1 is a diagram schematically illustrating a state in which a functional sheet manufacturing apparatus according to an embodiment of the present invention is viewed from the side. [Figure 4] 4 is an enlarged perspective view showing the vicinity of the bottom of a first functional material adhesive discharge means in the manufacturing apparatus shown in FIG. 3. FIG. [Figure 5] FIG. 1 is a diagram showing a schematic side view of a conventional (sinter method) functional sheet manufacturing apparatus. [Figure 6] 1 is a photograph showing the state in which the front-side base material sheet 110 has been peeled off from a conventional (sinter method) functional sheet, exposing the functional material layer. DETAILED DESCRIPTION OF THE INVENTION

[0020] 1. Overview A preferred embodiment of the present invention will be described in more detail with reference to the drawings. Fig. 1 is a cross-sectional view schematically showing a functional sheet 100 of this embodiment cut along a plane parallel to the thickness direction. Fig. 2 is a photograph showing a cross-section of the functional sheet 100 of this embodiment cut along a plane parallel to the thickness direction. In Fig. 2, for ease of understanding, the boundary between the first functional material layer 130a and the second functional material layer 130b is indicated by a gray curve.

[0021] The functional sheet 100 of this embodiment is breathable and can be used as an adsorption / removal filter installed in an air passage to adsorb and remove specific gases. As shown in FIG. 1 , the functional sheet 100 has a structure in which a functional material layer 130 is sandwiched between a pair of front and back substrate sheets (a front-side substrate sheet 110 and a back-side substrate sheet 120). Both the back-side substrate sheet 120 and the front-side substrate sheet 110 are breathable sheet-like members (breathable sheets). The functional material layer 130 has a multilayer structure in which a first functional material layer 130a, which is covered with a granular first functional material 131a, and a second functional material layer 130b, which is covered with a granular second functional material 131b of a type different from the first functional material 131a, are laminated.

[0022] As described above, the functional sheet 100 of this embodiment has a structure in which multiple types of functional materials 131a, 131b (first functional material 131a and second functional material 131b) are laminated in layers according to type, so that the gas to be treated can come into contact with each of the multiple types of functional materials 131a, 131b no matter which part of the functional sheet 100 the gas to be treated passes through. Therefore, the functions of the multiple types of functional materials 131a, 131b can be easily exerted evenly in the surface direction.

[0023] Additionally, in the functional sheet 100 of this embodiment, the first functional material 131a and the second functional material 131b each form a layer, so the contact area between the first functional material 131a and the second functional material 131b can be made smaller than when the first functional material 131a and the second functional material 131b are mixed together. This makes it possible to prevent the functions of the first functional material 131a and the second functional material 131b from deteriorating even when a combination of the first functional material 131a and the second functional material 131b is used in which the functions of one or both of the first functional material 131a and the second functional material 131b would be degraded if they were brought into contact with each other (for example, as shown in the examples below, a combination in which the first functional material 131a is an acid-adsorbing functional material and the second functional material 131b is a base-adsorbing functional material).

[0024] The first functional material layer 130a is provided with thread-like adhesive (first functional material adhesive 132a) that is randomly entangled with the first functional material 131a to connect the first functional materials 131a together. Also, the second functional material layer 130b is provided with thread-like adhesive (second functional material adhesive 132b) that is randomly entangled with the second functional material 131b to connect the second functional materials 131b together. This makes it difficult for the powder-like first functional material 131a and second functional material 131b to fall off from the functional sheet 100, and also improves the breathability of the functional sheet 100.

[0025] 1, in the functional sheet 100 of this embodiment, the functional material layer 130 and the front-side base material sheet 110 are also bonded with a thread-like adhesive (front-side adhesive 111), and the functional material layer 130 and the back-side base material sheet 120 are also bonded with a thread-like adhesive (back-side adhesive 121). This makes it possible to firmly bond the functional material layer 130 and the front-side base material sheet 110, and the functional material layer 130 and the back-side base material sheet 120, while preventing the breathability of the functional sheet 100 from decreasing.

[0026] The first functional material layer 130a and the second functional material layer 130b can be bonded together using the first functional material adhesive 132a and the second functional material adhesive 132b, without the need for a separate adhesive. However, in other embodiments, the first functional material layer 130a and the second functional material layer 130b can also be bonded together using a thread-like adhesive (interlayer adhesive). This allows for a more secure bond between the first functional material layer 130a and the second functional material layer 130b while preventing a decrease in the breathability of the functional sheet 100. The interlayer adhesive can have a structure similar to that of the front-side adhesive 111 or the back-side adhesive 121.

[0027] In this embodiment, synthetic rubber-based hot melt adhesives are used as the first functional material adhesive 132a, the second functional material adhesive 132b, the front-side adhesive 111, and the back-side adhesive 121. The front-side adhesive 111 may be arranged in any pattern as long as it is thread-like, and may be, for example, striped or lattice-like. In this embodiment, the front-side adhesive 111 is also in the form of a randomly tangled mesh, similar to the first functional material adhesive 132a and the second functional material adhesive 132b. The back-side adhesive 121 may also have a similar structure to the front-side adhesive 111.

[0028] The functional sheet 100 is not limited in its use. The use of the functional sheet 100 can be changed by changing the type of the first functional material 131a and the second functional material 131b used. For example, if the functional materials 131a and 131b are substances with a deodorizing function, such as activated carbon, the functional sheet 100 can be used as a deodorizing filter. If the functional materials 131a and 131b are substances with a water-absorbing function, such as silica gel or zeolite, the functional sheet 100 can be used as a moisture-absorbing filter. For convenience of explanation, the following description will be given taking as an example a case where powdered or granular activated carbon is used as the functional materials 131a and 131b and a deodorizing filter is manufactured as the functional sheet 100.

[0029] 2. Manufacturing method of functional sheets The manufacturing apparatus and manufacturing method for the functional sheet 100 of this embodiment will be described in detail below. Fig. 3 is a diagram schematically showing the state of the manufacturing apparatus for the functional sheet 100 of this embodiment as seen from the side. Fig. 4 is a perspective view showing an enlarged view of the vicinity of the bottom of the first functional material adhesive discharge means 40a in the manufacturing apparatus shown in Fig. 3.

[0030] 3 includes a base sheet transport means 10, a first functional material hopper 20a, a second functional material hopper 20b, a functional material dispersion means 30, a first functional material adhesive discharge means 40a, a second functional material adhesive discharge means 40b, a first functional material slider 50a, a second functional material slider 50b, a back-side adhesive discharge means 60, a front-side adhesive discharge means 70, an integrating base sheet feeding means 80, and a press means 90. Of these, the first functional material hopper 20a, the second functional material hopper 20b, the functional material dispersion means 30, the first functional material adhesive discharge means 40a, the second functional material adhesive discharge means 40b, the first functional material slider 50a, and the second functional material slider 50b are included in a functional material layer forming means for forming a functional material layer 130.

[0031] In the device shown in Figure 3, a first functional material adhesive discharge means 40a discharges a thread-like adhesive 132a for a first functional material onto a first functional material 131a (first functional material 131a in the air) as it falls from a first functional material hopper 20a toward a back-side base sheet 120. Therefore, even though the first functional material 131a and the first functional material adhesive 132a are dropped separately, when they fall onto the upper surface of the back-side base sheet 120 to form a first functional material layer 130a, the powder-like first functional material 131a are connected to each other by the thread-like adhesive 132a for a first functional material. Similarly, a second functional material adhesive discharge means 40b discharges a thread-like adhesive 132b for a second functional material onto a second functional material 131b (second functional material 131b in the air) as it falls from a second functional material hopper 20b toward the first functional material layer 130a. As a result, the powder-like second functional material 131b falls onto the first functional material layer 130a in a state where it is connected to itself by the thread-like second functional material adhesive 132b, and the second functional material layer 130b is formed.

[0032] 3, it is possible to form a functional material layer 130 having a structure in which a first functional material layer 130a, in which a first functional material 131a is spread, and a second functional material layer 130b, in which a second functional material 131b is spread, are laminated. As a result, as described above, it is possible to make it easier for the functions of the functional materials 131a and 131b to be exhibited evenly in the surface direction. It is also possible to make it harder for the functions of the first functional material 131a and the second functional material 131b to be deteriorated.

[0033] 3, the first functional material layer 130a and the second functional material layer 130b can be formed in a state in which the first functional materials 131a are connected to each other by thread-like first functional material adhesives 132a and the second functional materials 131b are connected to each other by thread-like second functional material adhesives 132b. This makes it possible to prevent the first functional materials 131a and the second functional materials 131b from falling off the functional sheet 100. This effect is particularly useful when increasing the amounts of the first functional materials 131a and the second functional materials 131b (activated carbon). Furthermore, by reducing the amount of adhesive used, it is possible to prevent the adhesive from blocking the voids (ventilation spaces) in the base sheets 110 and 120 (the front-side base sheet 110 and the back-side base sheet 120) and the gaps between the first functional materials 131a and the second functional materials 131b. This also improves the breathability of the resulting functional sheet 100. These make it possible to improve the performance (deodorizing performance and breathability) of the resulting functional sheet 100 (deodorizing filter).

[0034] 3, the first functional material 131a is already connected to the backside substrate sheet 120 by the first functional material adhesive 132a when it falls onto the top surface of the backside substrate sheet 120, and the second functional material 131b is already connected to the first functional material layer 130a by the second functional material adhesive 132b when it falls onto the top surface of the first functional material layer 130a. Therefore, even if a sheet-like member or the like is not placed on the first functional material layer 130a, the second functional material 131b is less likely to fall into the gaps between the first functional material 131a. This makes it possible to achieve a state in which no sheet-like member is interposed between the first functional material layer 130a and the second functional material layer 130b (the first functional material layer 130a and the second functional material layer 130b are in direct contact), thereby further improving the breathability of the functional sheet 100.

[0035] In the device shown in Figure 3, before the first functional material 131a is dropped onto the back-side base sheet 120, the back-side adhesive 121 is discharged in thread form onto the back-side base sheet 120 by the back-side adhesive discharge means 60. Next, the first functional material 131a is dropped onto the back-side base sheet 120 to form the first functional material layer 130a. Furthermore, the second functional material 131b is dropped onto the formed first functional material layer 130a to form the second functional material layer 130b. The front-side adhesive 111 is discharged in thread form onto the thus formed functional material layer 130 (the first functional material layer 130a and the second functional material layer 130b) by the front-side adhesive discharge means 70, and the front-side base sheet 110 is laid on top of it. This allows the functional material layer 130 to be firmly bonded to each of the back-side substrate sheet 120 and the front-side substrate sheet 110, thereby increasing the peel strength between the back-side substrate sheet 120 and the front-side substrate sheet 110. It also allows for firm adhesion between the first functional material layer 130a and the second functional material layer 130b. Additionally, the amount of adhesive used can be reduced, improving the breathability of the functional sheet 100. Furthermore, the back-side substrate sheet 120 and the front-side substrate sheet 110 can be firmly bonded together without applying strong pressure to them with the press means 90. This also allows the resulting functional sheet 100 to be flexible.

[0036] In another embodiment, when an interlayer adhesive is provided between the first functional material layer 130a and the second functional material layer 130b, an interlayer adhesive dispensing means is provided between the first functional material adhesive dispensing means 40a and the second functional material adhesive dispensing means 40b (after the first functional material adhesive dispensing means 40a and before the second functional material adhesive dispensing means 40b). This interlayer adhesive dispensing means is a means for dispensing the interlayer adhesive in a thread form onto the formed first functional material layer 130a. In this case, the second functional material 131b is dropped onto the first functional material layer 130a after the interlayer adhesive is dispensed onto the first functional material layer 130a. The configuration of the interlayer adhesive dispensing means can be the same as that described for the first functional material adhesive dispensing means 40a.

[0037] Each part of the device shown in FIG. 3 will now be described in detail.

[0038] 2.1 Base Sheet Transfer Means The base sheet transfer means 10 is for transferring the back-side base sheet 120. The mechanism of the base sheet transfer means 10 is not particularly limited. In this embodiment, the base sheet transfer means 10 is composed of a payout roller 11 and a take-up roller 12. A rotation drive means (such as an electric motor) (not shown) is attached to the take-up roller 12, and when this rotation drive means is driven, the take-up roller 12 is rotated. When the take-up roller 12 rotates, the back-side base sheet 120 is taken up by the take-up roller 12. Conversely, the back-side base sheet 120 wound around the pay-out roller 11 is pulled and paid out. In this way, the back-side base sheet 120 is transferred from the pay-out roller 11 toward the take-up roller 12. The transfer direction of the back-side base sheet 120 by the base sheet transfer means 10 is not particularly limited as long as it is a non-vertical direction. In this embodiment, the back-side base sheet 120 is transported in the horizontal direction, but it may also be transported in a direction inclined relative to the horizontal direction.

[0039] 2.2 First functional material hopper and second functional material hopper The first functional material hopper 20a is a tank-shaped member that stores the first functional material 131a, and is configured to discharge the first functional material 131a from a discharge port provided at the bottom. A discharge roller 21 is provided at the discharge port of the first functional material hopper 20a to prevent a large amount of the first functional material 131a from being discharged at once. Rotation of the discharge roller 21 allows the first functional material 131a to be discharged at a substantially constant flow rate. The first functional material 131a discharged from the first functional material hopper 20a falls by gravity and is scattered on the upper surface of the back-side substrate sheet 120. A suction means (not shown) is provided below the back-side substrate sheet 120, so that the falling first functional material 131a is attracted to the upper surface of the back-side substrate sheet 120. This prevents the first functional material 131a from scattering around the back-side substrate sheet 120.

[0040] The second functional material hopper 20b is a tank-like member that stores the second functional material 131b and is capable of discharging the second functional material 131b from a discharge port provided at the bottom. The second functional material hopper 20b can have the same configuration as that described for the first functional material hopper 20a.

[0041] 2.3 Functional material dispersion means The functional material dispersion means 30 is used to sieve and disperse the first functional material 131a dropped from the first functional material hopper 20a and the second functional material 131b dropped from the second functional material hopper 20b. This allows the first functional material 131a to fall substantially uniformly onto the upper surface of the back-side substrate sheet 120, and the second functional material 131b to fall substantially uniformly onto the upper surface of the first functional material layer 130a. The mechanism of the functional material dispersion means 30 is not particularly limited. In this embodiment, the functional material dispersion means 30 horizontally vibrates a punched metal with many small holes. The functional materials 131a and 131b pass through the small holes while being shaken. Since the functional materials 131a and 131b are in powder or granular form, they may fall onto the functional material dispersion means 30 in a state where multiple pieces have clumped together due to moisture or static electricity, but by passing them through the functional material dispersion means 30, the functional materials 131a and 131b can be dispersed separately.

[0042] 2.4 First functional material adhesive discharging means and second functional material adhesive discharging means The first functional material adhesive dispensing means 40a is configured to dispense the first functional material adhesive 132a in a thread-like (linear) form onto the first functional material 131a as it falls toward the upper surface of the back-side base sheet 120. This allows the first functional material adhesive 132a to become entangled with the falling first functional material 131a, thereby connecting the powder-like first functional materials 131a together. The mechanism of the first functional material adhesive dispensing means 40a is not particularly limited as long as it can dispense the first functional material adhesive 132a. In this embodiment, the synthetic rubber-based hot melt adhesive used as the first functional material adhesive 132a is initially in pellet or block form. This is melted into a liquid form using an applicator (not shown) and then supplied to the first functional material adhesive dispensing means 40a, from which the first functional material adhesive 132a is dispensed in a curtain spray manner. By doing so, it is not necessary to heat the adhesive 940 in a heating furnace 99 provided immediately before the pressure rollers 91 and 92, as in the filter manufacturing apparatus (sintering method) of FIG.

[0043] FIG. 4 shows an enlarged perspective view of the bottom portion of the adhesive discharge means 40a for the first functional material. As shown in FIG. 4, the adhesive discharge means 40a for the first functional material is a tank-shaped member 42 with a number of adhesive discharge ports 41 arranged at its bottom. The tank-shaped member 42 stores a first functional material adhesive 132a (a liquid-melted first functional material adhesive 132a). An air pump or other tank pressurizing means (not shown) applies pressure from above the first functional material adhesive 132a stored inside the tank-shaped member 42, causing the first functional material adhesive 132a to be discharged from the adhesive discharge ports 41. Air outlets 43 are provided on both sides of each adhesive discharge port 41. By spraying air from these air outlets 43, the first functional material adhesive 132a discharged from the adhesive discharge ports 41 can be shaken and dispersed. Therefore, at the discharge location α, it is possible to discharge the adhesive 132a for the first functional material onto the first functional material 131a substantially uniformly.

[0044] The adhesive discharge means 40b for the second functional material is configured to discharge the adhesive 132b for the second functional material in a thread-like (linear) form onto the second functional material 131b as it falls toward the upper surface of the first functional material layer 130a. The configuration of the adhesive discharge means 40b for the second functional material can be the same as that described for the adhesive discharge means 40a for the first functional material.

[0045] 2.5 Slider for first functional material and slider for second functional material The first functional material slider 50a guides the first functional material 131a that has passed through the functional material dispersion means 30 to a location α where the adhesive is discharged by the first functional material adhesive discharge means 40a. In this embodiment, the first functional material slider 50a is configured as an inclined plate that is inclined relative to the horizontal. This allows the first functional material 131a that has fallen from the functional material dispersion means 30 to be received on the upper surface of the inclined plate (first functional material slider 50a) and guided to the discharge location α by sliding along the upper surface of the inclined plate. The first functional material 131a has a width W1 immediately after falling from the functional material dispersion means 30. By providing this first functional material slider 50a, the width W2 of the first functional material 131a at the discharge location α can be made smaller than the width W1. If the width W2 of the first functional material adhesive 132a at the discharge location α is wide, there will likely be a difference in how the first functional material adhesive 132a adheres to the first functional material 131a between one side (the side closer to the first functional material adhesive discharge means 40a) and the other side (the side farther from the first functional material adhesive discharge means 40a) in a direction parallel to the width W2.However, the width W2 can be narrowed by using the first functional material slider 50a.

[0046] Furthermore, if the first functional material 131a were to fall vertically from the first functional material hopper 20a to the upper surface of the back-side base material sheet 120 without providing the first functional material slider 50a, it would be necessary to make the discharge direction of the first functional material adhesive 132a by the first functional material adhesive discharge means 40a non-vertical, making it difficult to control the discharge state of the first functional material adhesive 132a. In this regard, by providing the first functional material slider 50a and tilting the falling direction of the first functional material 131a relative to the vertical direction as described above, it is possible to make the discharge direction of the first functional material adhesive 132a by the first functional material adhesive discharge means 40a vertical.

[0047] The inclination angle θ1 (FIG. 3) of the first functional material slider 50a relative to the horizontal direction is not particularly limited. However, if the inclination angle θ1 is too small, the first functional material 131a will have difficulty sliding down the upper surface of the first functional material slider 50a. For this reason, the inclination angle θ1 is preferably 30° or more, and more preferably 40° or more. However, if the inclination angle θ1 is too large, it will be difficult to make the discharge direction of the first functional material adhesive 132a vertical. For this reason, the inclination angle θ1 is preferably 80° or less, and more preferably 70° or less. In this embodiment, the inclination angle θ1 of the first functional material slider 50a is set to approximately 45°. This makes it possible to make the discharge direction of the first functional material adhesive 132a approximately vertical.

[0048] The second functional material slider 50b guides the second functional material 131b that has passed through the functional material dispersion means 30 to the adhesive discharge location β by the second functional material adhesive discharge means 40b. The second functional material slider 50b can be configured in the same manner as the first functional material slider 50a. The inclination angle θ2 (FIG. 3) of the second functional material slider 50b is set equal to the inclination angle θ1 of the first functional material slider 50a. The inclination angle θ1 and the inclination angle θ2 may be substantially the same or different.

[0049] 2.6 Backside adhesive dispensing means The back-side adhesive dispensing means 60 is configured to pre-dispense thread-like back-side adhesive 121 onto the upper surface of the back-side base sheet 120 before the first functional material 131a is dropped. This allows the first functional material 131a (first functional material layer 130a) to be more firmly bonded to the back-side base sheet 120. However, in the device shown in FIG. 3, the first functional material adhesive dispensing means 40a and the second functional material adhesive dispensing means 40b cause the first functional material adhesive 132a to adhere to the first functional material 131a and the second functional material adhesive 132b to adhere to the second functional material 131b, thereby reducing the amount of back-side adhesive 121 dispensed by the back-side adhesive dispensing means 60. This makes it less likely that the back-side adhesive 121 will clog the gaps (ventilation spaces) in the back-side base sheet 120. The mechanism of the back-side adhesive dispensing means 60 is not particularly limited. In this embodiment, the same mechanism as the first functional material adhesive dispensing means 40a described above is also adopted for the back-side adhesive dispensing means 60. The dispensing direction of the back-side adhesive dispensing means 60 is also vertical, like the first functional material adhesive dispensing means 40a.

[0050] 2.8 Front adhesive dispensing means The front-side adhesive dispensing means 70 dispenses thread-like front-side adhesive 111 onto the upper surface of the functional material layer 130 (first functional material layer 130a and second functional material layer 130b) formed on the back-side base sheet 120. This allows the front-side base sheet 110 to be more firmly bonded to the functional material layer 130. However, in the device shown in FIG. 3, the first functional material adhesive dispensing means 40a adheres the first functional material adhesive 132a to the first functional material 131a, and the second functional material adhesive dispensing means 40b adheres the second functional material adhesive 132b to the second functional material 131b. This reduces the amount of front-side adhesive 111 dispensed by the front-side adhesive dispensing means 70. This makes it less likely that the front-side adhesive 111 will clog the voids (ventilation spaces) in the front-side base sheet 110. The mechanism of the front-side adhesive dispensing means 70 is not particularly limited. In this embodiment, the same mechanism as the first functional material adhesive dispensing means 40a described above is also adopted for the front-side adhesive dispensing means 70. The dispensing direction of the front-side adhesive dispensing means 70 is also vertical, like the first functional material adhesive dispensing means 40a.

[0051] 2.9 Integration base sheet feeding means The integrating substrate sheet feeding means 80 is used to feed the front-side substrate sheet 110 so that it overlaps the top surface of the functional material layer 130 after the front-side adhesive 111 has been discharged by the front-side adhesive discharging means 70. Together with a press means 90 (described later), this integrating substrate sheet feeding means 80 constitutes a "substrate sheet integrating means" that overlaps and integrates the front-side substrate sheet 110 with the back-side substrate sheet 120 and the functional material layer 130. The mechanism of the integrating substrate sheet feeding means 80 is not particularly limited. In this embodiment, as shown in FIG. 3 , the front-side substrate sheet 110 wound around a feed roller 81 is wound up together with the back-side substrate sheet 120 by a take-up roller 12, whereby the front-side substrate sheet 110 is fed from the feed roller 81 and overlapped on top of the functional material layer 130.

[0052] 2.10 Pressing Methods The press means 90 applies pressure to the overlapping back-side base material sheet 120 and front-side base material sheet 110. In this embodiment, as shown in Fig. 3, the press means 90 is composed of a pair of upper and lower pressure rollers 91, 92. The press means 90 applies pressure to the back-side base material sheet 120 and front-side base material sheet 110 by passing the back-side base material sheet 120 and front-side base material sheet 110, each containing a functional material layer 130, a back-side adhesive 121, and a front-side adhesive 111, through the gap between the pressure rollers 91, 92, thereby bonding the back-side base material sheet 120 and the functional material layer 130, and the front-side base material sheet 110 and the functional material layer 130 together. The front-side base material sheet 110 fed from the feed roller 81 is wrapped around the upper pressure roller 91. This allows tension to be applied to the front-side base material sheet 110, and the front-side base material sheet 110 can be neatly overlapped and integrated without wrinkles or the like.

[0053] As already mentioned, in the apparatus shown in FIG. 3 , the back-side adhesive 121 is attached to the back side (lower side) of the functional material layer 130, and the front-side adhesive 111 is attached to the front side (upper side) of the functional material layer 130. This allows the back-side substrate sheet 120 and the front-side substrate sheet 110 and the functional material layer 130 to be firmly bonded together without the need for strong pressure. Therefore, the apparatus shown in FIG. 3 allows the gap between the pressure rollers to be set wider than in conventional apparatuses. This prevents the resulting functional sheet 100 from becoming too hard (increasing the flexibility of the functional sheet 100). Furthermore, the breathability of the resulting functional sheet 100 can be adjusted by the applied pressure (the gap between the pressure rollers 91 and 92). The wider gap between the pressure rollers 91 and 92 can also further enhance the breathability of the functional sheet 100.

[0054] 3. Base sheet The type of the front-side substrate sheet 110 is determined appropriately depending on the application of the functional sheet 100, etc. When the functional sheet 100 is used as a filter such as a deodorizing filter, a nonwoven fabric is typically used as the front-side substrate sheet 110. Examples of nonwoven fabrics that can be used include those manufactured by a web obtained by a carding method, an airlaid method, a meltblown method, a spunbonding method, a flash spinning method, an electrospinning method, or the like, and then by a thermal bonding method such as a thermal bonding method, a binder bonding method such as a chemical bonding method, or a physical entanglement method such as a needle punching method or a hydroentanglement method. The material of the nonwoven fabric is not particularly limited, and can be polyester, vinylon, rayon, acrylic, nylon, polyolefin, etc., or a combination thereof. The type of the back-side substrate sheet 120 can be the same as that described for the front-side substrate sheet 110. The type of the front-side substrate sheet 110 and the type of the back-side substrate sheet 120 may be the same or different.

[0055] The weight per area of ​​the nonwoven fabric used as the back-side substrate sheet 120 is usually 10 g / m 2 More than 500g / m 2 The range is as follows: 10g / m 2 More than 200g / m 2 In this embodiment, as will be described later, the first functional material 131a and the second functional material 131b are sucked onto the upper surface of the back-side base sheet 120 by a suction means disposed below the back-side base sheet 120, so that the air permeability of the back-side base sheet 120 (a value measured by the Frazier method defined in JIS L 1913; the same applies hereinafter) is 100 cc / cm or less. 2 / s or more is preferable, and 150cc / cm 2 In this embodiment, the air permeability of the back-side base sheet 120 is set to about 200 cc / cm 2 The front-side base sheet 110 may have the same structure as the back-side base sheet 120.

[0056] Incidentally, the functional sheet 100 is often used as a filter material, and such filter material may be pleated (a process in which the functional sheet 100 is repeatedly folded into a sawtooth shape in side view to increase the surface area per unit area of ​​the filter material and improve the adsorption performance of the filter material). In this regard, if the front-side base material sheet 110 and the back-side base material sheet 120 of the functional sheet 100 are formed from a material with poor flexibility, pleating the functional sheet 100 may make the functional material layer 130 (the first functional material layer 130a and the second functional material layer 130b) more likely to peel off from the front-side base material sheet 110 and the back-side base material sheet 120.

[0057] For this reason, it is preferable that the elongation percentage (elongation percentage measured in accordance with JIS L1913 (2010)) of the front-side base sheet 110 and the back-side base sheet 120 (base sheets 110, 120) is 20% or more. When nonwoven fabric is used as the base sheets 110, 120, this is the elongation percentage in the machine direction (MD) of the nonwoven fabric. The same applies below.) of the front-side base sheet 110 and the back-side base sheet 120 (base sheets 110, 120) is 20% or more. This makes it possible to prevent the functional material layer 130 (first functional material layer 130a and second functional material layer 130b) from peeling off from the base sheets 110, 120 even when the functional sheet 100 is pleated. The elongation percentage of the base sheets 110, 120 is more preferably 25% or more, and even more preferably 30% or more. However, if the elongation percentage of the base sheets 110, 120 is too high, it may be difficult to increase the strength of the functional sheet 100. Therefore, the elongation percentage of the base sheets 110, 120 is preferably 80% or less, and more preferably 70% or less.

[0058] For the same reason, it is preferable to use a sheet material whose stiffness (stiffness measured by the Gurley method in accordance with JIS L1913 (2010)) of the base sheets 110, 120 is 6 [mN] or less. (When a nonwoven fabric is used as the base sheets 110, 120, the stiffness in the machine direction (MD) of the nonwoven fabric. The same applies below.) of the base sheets 110, 120 is more preferably 4 [mN] or less, and even more preferably 2 [mN] or less.

[0059] 4. Functional materials The first functional material 131a is not limited to a specific type or composition as long as it is a powder or granular material that can exhibit the desired function. For example, a powder or granular porous material can be used as the first functional material 131a. Examples of porous materials include activated carbon, zeolite, silica gel (porous silicon dioxide), diatomaceous earth, activated alumina, activated clay, aluminum silicate, magnesium silicate, ion exchange resin, and porous clay minerals. The first functional material 131a can be used alone or in combination of two or more types.

[0060] The function of the first functional material 131a is not particularly limited. Examples of the function of the first functional material 131a include an adsorption function (e.g., a deodorizing function or a moisture absorbing function), a filtering function, etc. The first functional material 131a may have only one type of function, or two or more types of functions.

[0061] When the first functional material 131a has an adsorption function (when the functional sheet 100 is used as an adsorption filter), the type of substance to be adsorbed by the first functional material 131a (the adsorbed substance) is not limited. The first functional material 131a can be, for example, one or more functional materials selected from the group consisting of a VOC-adsorbing functional material having a VOC adsorption function, an acid-adsorbing functional material having an acidic gas adsorption function, a base-adsorbing functional material having a basic gas adsorption function, and a neutral-adsorbing functional material having a neutral gas adsorption function. Examples of VOCs include isobutanol, ethyl acetate, methyl isobutyl ketone, toluene, styrene, and xylene. Examples of acidic gases include sulfur compounds (such as hydrogen sulfide and alkanethiols), nitrogen compounds, acetic acid, hydrogen chloride, propionic acid, butyric acid, and valeric acid. Examples of basic gases include ammonia and amine-based compounds. Examples of neutral gases include sulfur-based neutral gases (methyl sulfide, methyl disulfide, etc.), aldehydes, etc. The substance to be adsorbed by the first functional material 131a can be one type or two or more types.

[0062] When a granular porous body is used as the first functional material 131a, the granular porous body can be either untreated or treated with a chemical. By treating with a chemical, the adsorption characteristics of the porous body can be changed, thereby increasing the adsorption efficiency of a specific adsorbate. The specific method of chemical treatment is not limited. Examples of types of chemical treatment include attachment, impregnation, and support (supporting a chemical on a granular porous body).

[0063] For example, when an acidic gas is used as the adsorbed substance, examples of chemicals used in the chemical treatment include basic chemicals such as metal carbonates (e.g., alkali metal carbonates such as potassium carbonate, potassium bicarbonate, sodium carbonate, and sodium bicarbonate) and metal hydroxides (e.g., sodium hydroxide and potassium hydroxide). When a basic gas is used as the adsorbed substance, examples of chemicals used in the chemical treatment include acidic chemicals such as phosphoric acid, citric acid, malic acid, tartaric acid, ascorbic acid, sulfuric acid, nitric acid, ferrous chloride, and ferrous sulfate. When an aldehyde gas is used as the adsorbed substance, examples of chemicals used in the chemical treatment include amine compounds (e.g., primary amine compounds such as acid hydrazide compounds, ethanolamine, polyethyleneimine, aniline, anisidine, and the like). The granular porous body can be treated with only one type of chemical, or with a combination of two or more types of chemicals.

[0064] The size (particle size) of the first functional material 131a is not limited. However, if the first functional material 131a is too small, the first functional material 131a may easily fall off the functional sheet 100 or may be difficult to handle. For this reason, the size of the first functional material 131a is preferably a size that fits over a 200-mesh sieve specified in JIS Z8801, more preferably a 150-mesh sieve, and even more preferably a 100-mesh sieve. Furthermore, the particle size of the first functional material 131a is preferably 50 μm or more, and more preferably 100 μm or more.

[0065] On the other hand, if the first functional material 131a is too large, it becomes difficult to ensure a large specific surface area for the first functional material 131a, which may result in difficulty in enhancing the function of the first functional material 131a exerted per unit area of ​​the functional sheet 100. For this reason, the size of the first functional material 131a is preferably under a 5-mesh sieve specified in JIS Z8801, more preferably under a 7.5-mesh sieve, and even more preferably under a 10-mesh sieve. Furthermore, the particle size of the first functional material 131a is preferably 5 mm or less, more preferably 3 mm or less.

[0066] The second functional material 131b can have the same configuration as that described for the first functional material 131a. However, a different type of functional material from that of the first functional material 131a is used as the second functional material 131b. There are no limitations on how the first functional material 131b and the second functional material 131b differ. The first functional material 131b and the second functional material 131b can differ, for example, in material (for example, the type of granular porous material when used), function, size (particle size), etc.

[0067] An example of a case in which the functions of the first functional material 131b and the second functional material 131b are different is when the adsorbate (or a combination thereof, if multiple adsorbates) to be adsorbed by the first functional material 131a is not the same as the adsorbate (or a combination thereof, if multiple adsorbates) to be adsorbed by the second functional material 131b. More specifically, the first functional material 131a can be one functional material selected from the group consisting of VOC-adsorbing functional materials, acid-adsorbing functional materials, base-adsorbing functional materials, and neutral-adsorbing functional materials, and the second functional material 131b can be another functional material selected from the same group. Alternatively, the first functional material 131a can be an untreated porous material and the second functional material 131b can be a chemically treated porous material. Alternatively, the first functional material 131a can be a chemically treated porous material and the second functional material 131b can be an untreated porous material. Alternatively, the first functional material 131a can be a chemically treated porous material and the second functional material 131b can be a chemically treated porous material that is different from the first functional material 131a.

[0068] The unit area (1 m) of the functional sheet 100 2 The retention amount F of the functional materials 131a, 131b per layer (the total amount of the multiple types of functional materials contained in the functional material layer 130; in this embodiment, the total amount of the first functional material 131a that falls from the first functional material hopper 20a (FIG. 3) and is scattered onto the back-side substrate sheet 120 and the second functional material 131b that falls from the second functional material hopper 20b and is scattered onto the first functional material layer 130a; the same applies below) is not particularly limited. As already mentioned, in the device shown in FIG. 3, the powder-like first functional materials 131a are connected to each other with thread-like first functional material adhesive 132a, and the second functional materials 131b are connected to each other with thread-like second functional material adhesive 132b, so that even if the scattering amounts of the functional materials 131a, 131b are increased, the functional materials 131a, 131b are less likely to fall off. The amount of the functional materials 131a and 131b held, F, is, for example, 50 [g / m 2 ] or more, or 100 [g / m 2 ] or more, or 150 [g / m 2 ] or more, or 200 [g / m 2 ] or more, or 250 [g / m2 In the functional sheet 100 of this embodiment, the amount of the functional materials 131a and 131b held by the sheet 100 can be set to 600 [g / m 2 It was confirmed that even when the holding amount F of the functional materials 131a and 131b is 5000 [g / m ] or more, it is possible to prevent the functional materials 131a and 131b from falling off. However, if the holding amount F of the functional materials 131a and 131b becomes too large, there is a risk that the functional materials 131a and 131b will easily fall off from the functional sheet 100. For this reason, the holding amount F of the functional materials 131a and 131b is set to 5000 [g / m 2 ] or less, and 3000 [g / m 2 ] or less is more preferable.

[0069] 5. Adhesive The type of first functional material adhesive 132a varies depending on the application of the functional sheet 100 and the types of base sheets 110 and 120, but a hot melt type is preferably used. Examples of hot melt type adhesives include synthetic rubber hot melt adhesives, polyolefin hot melt adhesives, and EVA hot melt adhesives. Of these, synthetic rubber hot melt adhesives and polyolefin hot melt adhesives can be preferably used as the first functional material adhesive 132a. In particular, synthetic rubber hot melt adhesives are highly adhesive and therefore very suitable as the first functional material adhesive 132a.

[0070] Examples of base polymers (synthetic rubber) that can be used for synthetic rubber-based hot melt adhesives include styrene-isoprene-styrene block copolymer (SIS), styrene-ethylene-propylene-styrene block copolymer (SEPS), styrene-butadiene-styrene block copolymer (SBS), and styrene-ethylene-butylene-styrene block copolymer (SEBS). A single base polymer can be used, or two or more can be combined. Among these, SIS is particularly suitable as the base polymer for the first functional material adhesive 132a because of its high tensile elongation and excellent adhesive properties.

[0071] The first functional material adhesive 132a may contain various additives. Examples of additives include tackifiers (e.g., terpene resins, rosin resins, petroleum resins, etc.), plasticizers (e.g., paraffin oils, naphthene oils, aromatic oils, polybutene, polyisobutylene, etc.), and stabilizers (e.g., antioxidants, ultraviolet absorbers, etc.). One type of additive may be used alone, or two or more types may be used in combination.

[0072] In this embodiment, a mixture of styrene-isoprene-styrene block copolymer (SIS) and terpene resin is used as the first functional material adhesive 132a. It has also been confirmed that this first functional material adhesive 132a generates almost no volatile organic compounds (VOCs) that can have adverse effects on the environment and human body.

[0073] The same configuration as that described for the first functional material adhesive 132a can be adopted for the second functional material adhesive 132b, the back-side adhesive 121, and the front-side adhesive 111. The first functional material adhesive 132a, the second functional material adhesive 132b, the back-side adhesive 121, and the front-side adhesive 111 may be the same type or different types.

[0074] The content of adhesive in the functional sheet 100 (total content of the adhesive 132a for the first functional material, the adhesive 132b for the second functional material, the back-side adhesive 121, and the front-side adhesive 111; the same applies below) is not particularly limited. However, if the content of adhesive is too small, there is a risk that the functional materials 131a, 131b may easily fall off, that the functional material layer 130 may easily peel off from the front-side base sheet 110 or the back-side base sheet 120, or that the first functional material layer 130a and the second functional material layer 130b may easily peel off from each other. For this reason, the adhesive content per unit area (1 m) of the functional sheet 100 is low. 2 ) adhesive content [g / m 2 ] is the amount of functional material retained F [g / m 2] is preferably 0.1% or more, more preferably 0.5% or more, and even more preferably 1% or more. On the other hand, if the content of adhesive is too high, it may be difficult to improve the breathability of the functional sheet 100. For this reason, the content of adhesive in the functional sheet 100 [g / m 2 ] is the amount of functional material retained F [g / m 2 ] is preferably 40% or less, more preferably 30% or less, and even more preferably 20% or less.

[0075] 6. Physical properties of functional sheets The functional sheet 100 of this embodiment can achieve high breathability (i.e., small pressure loss) even when the amount F of the functional materials 131a and 131b held is large. For example, in the functional sheet 100 of this embodiment, when the amount F of the functional materials 131a and 131b held is 100 [g / m 2 ] or more 150[g / m 2 ] or less, the pressure loss D (surface wind speed 5.3 [cm / s], measurement area 100 [cm 2 The pressure loss measured under the conditions of (1) above can be set to 4 [Pa] or less. 2 ] more than 300 [g / m 2 When the amount F of the functional materials 131a and 131b held is 300 [g / m 2 ] or less, the pressure loss D can be set to 8 [Pa] or less, or 6 [Pa] or less. 2 ] more than 600 [g / m 2 When the amount F of the functional materials 131a and 131b held is 600 [g / m 2 ] or less, the pressure loss D can be set to 20 [Pa] or less, or 10 [Pa] or less. 2 ] more than 800 [g / m 2 ] or less, the pressure loss D can be set to 30 [Pa] or less, 20 [Pa] or less, or 12 [Pa] or less.

[0076] In the above, an example was described in which the functional material layer 130 has a two-layer structure having a first functional material layer 130a and a second functional material layer 130b. However, the functional material layer 130 is not limited to a two-layer structure and can also have a three-layer or more structure. In this case, the third functional material layer (not shown),...nth functional material layer (n≧3) sequentially stacked on the second functional material layer 130b can have the same structure as that described for the first functional material layer or the second functional material layer. As the third functional material...nth functional material (n≧3) spread over the third functional material layer...nth functional material layer (n≧3), different types of materials should be used at least between adjacent layers. [Example]

[0077] The present invention will be described in more detail below with reference to more specific examples, but the embodiments of the present invention are not limited to the following examples.

[0078] [Experiment 1] Using acid-adsorbing activated carbon, which adsorbs acidic gases, and untreated activated carbon, which adsorbs VOCs and the like, functional sheets of the example and comparative example were manufactured using the apparatus shown in Figure 3 and the sinter method (Figure 5), respectively, and the changes in the adsorption functions of the functional sheets of the example and comparative example were investigated over time.

[0079] <Production of functional sheets> Example 1 The functional sheet of Example 1 was produced using a powdered activated carbon for acid adsorption as the first functional material and a powdered untreated activated carbon as the second functional material, using the apparatus shown in Figure 3. The functional material loading F was 350 [g / m 2 The adhesive for the first functional material, the adhesive for the second functional material, the front side adhesive, and the front side adhesive were all made by mixing SIS with a terpene resin. The adhesive content [g / m 2 ] is the amount of functional material retained F [g / m 2 ] was set at approximately 10%.

[0080] (Comparative Example 1) Instead of the device shown in Fig. 3, the functional sheet of Comparative Example 1 was produced using the device shown in Fig. 5 (sintering method). The conditions were the same as those in Example 1, except that the acid-adsorbing activated carbon, untreated activated carbon, and adhesive were sprayed in a pre-mixed state, and an EVA-based hot melt adhesive was used as the adhesive.

[0081] <Measurement of SO2 adsorption function> For each of the functional sheets of Example 1 and Comparative Example 1, air containing sulfur dioxide (SO2), an acidic gas, was continuously passed through for 90 minutes. The area of the functional sheet used was 100 [cm 2 , the concentration of sulfur dioxide in the air was 30 [ppm], and the flow rate of the air containing sulfur dioxide was 30 [L / min]. The concentration of sulfur dioxide in the air after passing through the functional sheet was measured at 0.5 minutes, 1 minute, 5 minutes, 15 minutes, 30 minutes, 60 minutes, and 90 minutes after starting the air flow, and the removal rate of sulfur dioxide at that time was calculated. The results are shown in Table 1 below. In Comparative Example 1, since the SO2 removal rate became approximately 0% at 65 minutes, the measurement after 90 minutes was not performed.

[0082]

Table 1

[0083] As shown in Table 1 above, in the functional sheet of Example 1, the SO2 adsorption function was maintained even after 90 minutes from the start of air flow, while the adsorption function of Comparative Example 1 decreased to approximately 0% at 65 minutes. The SO2 adsorption capacity of the functional sheet of Example 1 was 20.4 [g / m 2 , whereas the SO2 adsorption capacity of the functional sheet of Comparative Example 1 was 8.4 [g / m 2 . ​​​​Using activated carbon for acid adsorption with acidic gas as the adsorbed substance and activated carbon for base adsorption with basic gas as the adsorbed substance, the functional sheet of the example was produced by the apparatus shown in Fig. 3, and the functional sheet of the comparative example was produced by the sintering method (Fig. 5), and it was investigated how the adsorption function of the functional sheets of the example and the comparative example changed with the passage of time.

[0085] <Fabrication of Functional Sheet> (Example 2) Powdery activated carbon for acid adsorption was used as the first functional material, and powdery activated carbon for base adsorption was used as the second functional material, and the functional sheet of Example 2 was fabricated using the apparatus shown in Fig. 3. The holding amount F of the functional material was 245 [g / m 2 . For the adhesive for the first functional material, the adhesive for the second functional material, the front-side adhesive, and the front-side adhesive, all were those obtained by mixing terpene resin into SIS. The content of the adhesive [g / m 2 was set to about 10% of the holding amount F [g / m 2 of the functional material.

[0086] (Comparative Example 2) The functional sheet of Comparative Example 2 was fabricated using the apparatus shown in Fig. 5 (sintering method) instead of the apparatus shown in Fig. 3. The conditions were the same as those in Example 2 except that the powdery activated carbon for acid adsorption, the powdery activated carbon for base adsorption, and the adhesive were sprayed in a pre-mixed state, and an EVA-based hot melt adhesive was used as the adhesive.

[0087] <Measurement of SO2 Adsorption Function> For each of the functional sheets of Example 2 and Comparative Example 2, air containing sulfur dioxide (SO2) was continuously passed through for 180 minutes. The area of the functional sheet used was 100 [cm 21. The concentration of sulfur dioxide in the air was 10 [ppm], and the flow rate of the air containing sulfur dioxide was 30 [L / min]. The concentration of sulfur dioxide in the air after passing through the functional sheet was measured at each time point of 0.5 minutes, 1 minute, 5 minutes, 15 minutes, 30 minutes, 60 minutes, 90 minutes, 120 minutes, 150 minutes, and 180 minutes after starting to flow the air, and the removal rate of sulfur dioxide at that time point was calculated. The results are shown in Table 2 below. In Comparative Example 2, since the SO2 removal rate became approximately 0% at the 130 - minute time point, the measurements at 150 minutes and 180 minutes were not performed.

[0088]

Table 2

[0089] <Measurement of NH3 Adsorption Function> For each of the functional sheets of Example 2 and Comparative Example 2, air containing ammonia (NH3) was continuously passed through for 180 minutes. The area of the functional sheet used was 100 [cm 2 . The concentration of ammonia in the air was 10 [ppm], and the flow rate of the air containing ammonia was 30 [L / min]. The concentration of ammonia in the air after passing through the functional sheet was measured at each time point of 0.5 minutes, 1 minute, 5 minutes, 15 minutes, 30 minutes, 60 minutes, 90 minutes, 120 minutes, 150 minutes, and 180 minutes after starting to flow the air, and the removal rate of ammonia at that time point was calculated. The results are shown in Table 3 below. In Example 2, since the NH3 removal rate became approximately 0% at the 130 - minute time point, the measurements at 150 minutes and 180 minutes were not performed. Also, in Comparative Example 2, since the NH3 removal rate became approximately 0% at the 70 - minute time point, the measurements at 90 minutes, 120 minutes, 150 minutes, and 180 minutes were not performed.

[0090]

Table 3

Explanation of Reference Signs

[0091] 10 Substrate Sheet Transfer Means 11. Feed roller (for back side base sheet) 12 Winding roller 20a First functional material hopper 20b Secondary functional material hopper 21 Discharge roller 30 Functional material dispersion means 40a First functional material adhesive discharging means 40b Second functional material adhesive discharging means 41 Adhesive outlet 42 Tank-shaped member 43 Air outlet 50a First Functional Material Slider 50b Secondary functional material slider 60 Back side adhesive discharging means 70 Front side adhesive discharge means 80 Integration base sheet feeding means 81 Feed roller (for front side base sheet) 90 Pressing Methods 91 Pressure roller (upper side) 92 Pressure roller (lower) 99 Heating Furnace 100 Functional Sheet 110 Front side base sheet (base sheet) 111 Front side adhesive 120 Back side base sheet (base sheet) 121 Backside adhesive 130 Functional material layer 130a First functional material layer 130b Second functional material layer 131a First functional material 131b Second functional material 132a First functional material adhesive 132b Adhesives for secondary functional materials 900 Functional Sheet 910 Base Sheet 920 Base sheet 930 Functional Materials 940 Adhesive α: The location where the adhesive is discharged by the first functional material adhesive discharge means β. The location where the adhesive is discharged by the adhesive discharge means for the second functional material θ1 Tilt angle of the slider for the first functional material θ2 Tilt angle of slider for secondary functional material

Claims

1. A breathable functional sheet in which a functional material layer is sandwiched between a front substrate sheet and a back substrate sheet, The functional material layer is a first functional material layer in which granular first functional materials are spread; A second functional material layer in which a different type of powder-like second functional material from the first functional material is spread out. has a laminated structure A functional sheet characterized by:

2. the first functional material layer includes a thread-like adhesive that is entangled with the first functional materials to connect the first functional materials together; The second functional material layer is provided with a thread-like adhesive that is entangled with the second functional materials to connect the second functional materials together. The functional sheet according to claim 1.

3. 3. The functional sheet according to claim 2, wherein the functional material layer and the front substrate sheet, and the functional material layer and the back substrate sheet are bonded together by a thread-like adhesive, respectively.

4. 3. The functional sheet according to claim 2, wherein no sheet-like member is interposed between the first functional material layer and the second functional material layer.

5. The first functional material and the second functional material both have an adsorption function, The substance to be adsorbed by the first functional material is not the same as the substance to be adsorbed by the second functional material. The functional sheet according to claim 1.

6. A method for producing the functional sheet according to any one of claims 1 to 5.

7. A functional sheet manufacturing apparatus for manufacturing a breathable functional sheet in which a functional material layer is sandwiched between a front-side substrate sheet and a back-side substrate sheet, a base sheet transport means for transporting the back side base sheet; a functional material layer forming means for forming a functional material layer on the back-side substrate sheet; a substrate sheet integration means for stacking the front-side substrate sheet on the upper side of the functional material layer to integrate the back-side substrate sheet, the functional material layer, and the front-side substrate sheet; Equipped with The functional material layer forming means is a first functional material hopper for dropping a powdery first functional material onto the upper side of the back-side base sheet being transferred by the base sheet transfer means, thereby forming a first functional material layer in which the first functional material is spread over; a second functional material hopper for dropping a powdery second functional material onto the upper side of the first functional material layer to form a second functional material layer in which the second functional material is spread over the first functional material layer in a laminated state; A functional sheet manufacturing apparatus comprising:

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