Rolls and base materials for those rolls

Abstract

To provide a roll with superior water and oil extraction capabilities. Also, to provide a base material for a roll that can be used to manufacture such a roll. [Solution] The present invention is a roll base material consisting of a fiber sheet containing 50 to 80 mass% unbleached cotton fibers. Preferably, the fibers constituting the fiber sheet are bonded and fixed with nitrile rubber. Furthermore, the roll of the present invention is made by laminating a large number of the roll base materials, each having a circular outer shape, on a shaft.

Description

Technical Field

[0001] The present invention relates to a roll capable of extracting moisture and oil, and a base material for the roll.

Background Art

[0002] Conventionally, for example, in the manufacturing process of steel plates and the like, rolls are used to extract moisture and oil adhering to the surface. For example, a roll laminated with a non-woven fabric using corma yarn made of cotton is known (Japanese Patent Application Laid-Open No. 2015-113919). However, there has been a demand for rolls with excellent extractability of moisture and oil.

Prior Art Documents

Patent Documents

[0003] Japanese Patent Application Laid-Open No. 2015-113919

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a roll having higher extractability of moisture and oil. Another object is to provide a base material for a roll capable of manufacturing such a roll.

Means for Solving the Problems

[0005] The base material for the roll according to the present invention is composed of a fiber sheet containing 50 to 80 mass% of unbleached cotton fibers. It is preferable that the constituent fibers of the fiber sheet are adhesively fixed with nitrile rubber.

[0006] The roll of the present invention is formed by laminating a large number of the above-mentioned roll base materials having a circular outer shape on a shaft.

Effects of the Invention

[0007] The present invention has found that a roll base material made of a fiber sheet containing 50-80 mass% unbleached cotton fibers can be used to produce rolls with superior moisture and oil extraction capabilities. The unbleached cotton fibers that make up the roll base material of the present invention are cotton fibers that have not been bleached, and because cotton fibers inherently contain a large amount of natural oils, they have excellent oil extraction capabilities. Furthermore, since cotton fibers also have excellent water absorption, they have excellent moisture extraction capabilities.

[0008] Furthermore, because the constituent fibers of the fiber sheet are bonded and fixed with nitrile rubber, it is possible to create rolls that are highly durable and have a long lifespan, as they are less prone to deformation and fraying of the fibers even after prolonged use.

[0009] The roll of the present invention is superior in its ability to extract moisture and oil because it is constructed by laminating many of the roll base materials of the present invention onto a shaft. [Brief explanation of the drawing]

[0010] [Figure 1] (a) Plan view of an element punched out from the roll substrate of the present invention (b) Plan view of another element punched out from the roll substrate of the present invention [Figure 2] Front view of the roll of the present invention [Modes for carrying out the invention]

[0011] The base material for rolls of the present invention is primarily composed of unbleached cotton fibers, meaning that 50 masss or more of the fibers constituting the fiber sheet are unbleached cotton fibers, in order to produce rolls with excellent moisture and oil extraction properties. The greater the amount of unbleached cotton fibers, the better the moisture and oil extraction properties, so it is preferable that unbleached cotton fibers constitute 60 masss or more of the fibers constituting the fiber sheet. On the other hand, if the fiber sheet contains more than 80 masss of unbleached cotton fibers, the roll will deform or the fibers will fray during use, resulting in poor durability. Therefore, 80 masss or less of the fibers constituting the fiber sheet are unbleached cotton fibers, preferably 70 masss or less.

[0012] Other fibers that make up the fiber sheet besides unbleached cotton fibers include, for example, nylon fibers (including nylon 6 fibers, nylon 66 fibers, tire cords, and recycled fibers), polyester fibers, vinylon fibers, or polyolefin fibers such as polyethylene fibers and polypropylene fibers. Among these, nylon fibers, which have excellent abrasion resistance, are preferred, and nylon 6 fibers are particularly preferred.

[0013] The fineness of the fibers other than the unbleached cotton fibers is not particularly limited, but it is preferably 1 to 10 dtex, and more preferably 3 to 6 dtex, in order to produce a roll with excellent durability. The fibers other than the unbleached cotton fibers may be staples or filaments, but it is preferable that they be staples so that they can be uniformly mixed with the unbleached cotton fibers, have excellent moisture and oil extraction properties, and have excellent durability. In the case of staples, they are preferably about 30 to 110 mm in length. In this invention, staple-like fibers (such as rayon) obtained by cutting filaments may also be used.

[0014] The base material for rolls of the present invention is a fiber sheet made of the fibers described above. This fiber sheet can be, for example, a woven fabric, a knitted fabric, a nonwoven fabric, or a composite thereof, but among these, a nonwoven fabric with excellent elasticity and exploitability is preferred.

[0015] The fiber sheet of the present invention can be manufactured by conventional methods, but a preferred method for manufacturing nonwoven fabrics will be described below.

[0016] First, a fiber web is formed from the fibers described above (unbleached cotton fibers and fibers other than unbleached cotton fibers). Methods for forming this fiber web include dry methods such as the carding method and the air-laying method, as well as wet methods. Among these, nonwoven fabrics derived from fiber webs formed by the dry method are preferred because they have excellent elasticity and exfoliation properties. After forming the fiber web, different types of fiber webs may be laminated, such as laminating fiber webs made by different manufacturing methods or laminating fiber webs with different fiber compositions.

[0017] Furthermore, it is preferable that the orientation of the fibers in the fiber web be multidirectional. This is because the multidirectional orientation allows for superior extraction of moisture and oil from various directions. Such a fiber web may include, for example, a cross fiber web formed by crossing unidirectional fiber webs in a cross-layer structure.

[0018] Next, these fiber webs are bonded together to form a nonwoven fabric. Methods of bonding include, for example, entanglement using needles or fluid flow, fusion of the fibers constituting the fiber web, bonding with a binder, stitching, or a combination of these methods. Among these, bonding with a binder is preferable because the binder provides elasticity, resulting in excellent extensibility and a longer service life.

[0019] Examples of the polymer used to form the binder include nitrile rubber, styrene-butadiene rubber, butylene rubber, isoprene rubber, ethylene-propylene copolymer, ethylene-propylene-diene copolymer, nitrile-butadiene rubber, chloroprene rubber, butyl rubber, urethane rubber, silicone rubber, polysulfide rubber, hydrogenated nitrile rubber, fluororubber, tetrafluoroethylene-propylene rubber, acrylic rubber, chlorosulfonated polyethylene rubber, polyether special rubber, epichlorohydrin rubber, propylene oxide rubber, ethylene-acrylic rubber, liquid rubber, norbornene rubber, thermoplastic elastomer, and the like. Among these, nitrile rubber is preferred because it has elasticity, high self-recovery ability, and excellent water resistance, oil resistance, and heat resistance.

[0020] Although the adhesion rate of this polymer is not particularly limited, it is preferably 20 to 70 mass% of the entire fiber sheet adhesively fixed with the binder, more preferably 30 to 60 mass%, and still more preferably 40 to 50 mass% so as to have excellent elasticity, squeezing property, and long service life. If it is less than 20 mass%, improvement in elasticity and squeezing property may not be expected much. If it exceeds 70 mass%, the polymer may cover the unbleached cotton fibers, and the squeezing performance of moisture and oil by the unbleached cotton fibers may not be fully exhibited. This adhesion rate refers to the percentage when the mass of the entire fiber sheet after the polymer adheres is taken as 100.

[0021] The method of adhesively fixing with a binder containing such a polymer can be carried out, for example, by impregnating, spraying, or coating the latex binder of the polymer as described above on the fiber web and then drying.

[0022] The basis weight of such a fiber sheet (base material for roll) of the present invention is preferably 50 to 800 g / m 2 If the basis weight is less than 50 g / m 2 the strength may be low and the morphological stability may be poor. If it exceeds 800 g / m 2When it exceeds this value, there is a tendency for variations in hardness to occur in the thickness direction. Therefore, it is more preferably 100 to 400 g / m 2 and even more preferably 150 to 300 g / m 2 .

[0023] Also, the thickness is preferably 0.5 to 4 mm. If the thickness is less than 0.5 mm, the strength may be low and the morphological stability may deteriorate. If it exceeds 4 mm, there is a tendency for variations in hardness to occur in the thickness direction. Therefore, it is more preferably 0.8 to 3 mm and even more preferably 1 to 2 mm. The thickness refers to the value under a 2.0 kPa load.

[0024] Such a fiber sheet (substrate for roll) preferably has a tensile strength of 100 N / 50 mm width or more, more preferably 120 N / 50 mm width or more, and even more preferably 150 N / 50 mm width or more in both the longitudinal direction and the transverse direction so as to have excellent durability. The longitudinal direction means the production direction during the production of the fiber sheet, and the transverse direction means the direction perpendicular to the longitudinal direction.

[0025] This tensile strength refers to the strength required for breakage when both ends of a test piece of a fiber sheet cut to a width of 50 mm are fixed to the chucks of a tensile strength tester (chuck distance = 100 mm) and pulled at a speed of 200 mm / min. Such measurement of the tensile strength is performed on three test pieces taken from the fiber sheet, and the arithmetic mean value is taken as the tensile strength in the present invention.

[0026] Also, the fiber sheet (substrate for roll) preferably has an elongation rate of 100% or less, more preferably 80% or less, and even more preferably 60% or less in both the longitudinal direction and the transverse direction so as to have excellent durability.

[0027] In the tensile strength measurement test described above, this elongation rate represents the percentage of the distance between the chucks (=Smax, unit: cm) at the time the test piece breaks relative to the initial distance between the chucks (X: 10 cm). This elongation rate is measured for three test pieces taken from a fiber sheet, and the arithmetic mean is defined as the elongation rate (Sr) in this invention. Sr=[(Smax-X) / X]×100=10(Smax-10)

[0028] The roll of the present invention has a circular outer shape, and a large number of these roll base materials are laminated on a shaft. As mentioned above, the roll base material of the present invention has excellent water and oil extraction properties, and therefore the roll of the present invention has excellent water and oil extraction properties.

[0029] In this invention, for example, a roll can be manufactured by punching out a roll base material into a roughly donut shape (see Figure 1(a)) or a donut shape with a roughly regular polygonal outer circumference (see Figure 1(b)) to form a large number of elements (1), then stacking a large number of elements (1) on a shaft (2) (see Figure 2), applying pressure in the stacking direction using a hydraulic press or the like, and then grinding the roll surface with a lathe or sandpaper to make the outer shape of each element (roll base material) circular, thereby manufacturing the roll.

[0030] Examples of the present invention are described below, but the present invention is not limited to these examples. [Examples]

[0031] (Examples 1-3, Comparative Examples 1-2) Unbleached cotton fibers, bleached cotton fibers, and / or nylon 6 fibers with a fineness of 2.8 dtex and a fiber length of 64 mm were blended in the proportions shown in Table 1, opened using a carding machine to form a unidirectional fiber web, and this unidirectional fiber web was crossed with a cross layer to form a cross fiber web.

[0032] [Table 1]

[0033] This cross fiber web was immersed in a nitrile rubber latex binder bath to impregnate the fiber web with the nitrile rubber latex binder. After that, it was dried in a can dryer set to a temperature of 150°C to produce a nonwoven fabric (base material for rolls) in which the fibers were bonded and fixed together with nitrile rubber. The physical properties of these nonwoven fabrics (base materials for rolls) are shown in Table 2.

[0034] [Table 2]

[0035] (Moisture-removing test) From the nonwoven fabrics (roll base materials) of Examples 1-3 and Comparative Examples 1-2, five rectangular vertical test specimens with a length of 200 mm and a width of 25 mm, and five rectangular horizontal test specimens with a length of 25 mm and a width of 200 mm were taken.

[0036] Then, the height to which water rose (water absorption height) of the longitudinal and transverse test specimens was measured using the Baylec method described in JIS L 1907(2010)7.1.2.

[0037] The water absorption height was measured for five longitudinal and transverse test specimens, and the arithmetic mean was used to calculate the respective water absorption heights.

[0038] Based on the measurement results, nonwoven fabrics (roll base materials) with an absorption height of less than 40 mm were evaluated as having insufficient wringability (△), nonwoven fabrics (roll base materials) with an absorption height of 40 mm or more but less than 60 mm were evaluated as having good wringability (〇), and nonwoven fabrics (roll base materials) with an absorption height of 60 mm or more were evaluated as having very good wringability (◎). These results are shown in Table 3.

[0039] (Oil extraction test) From the nonwoven fabrics (roll base materials) of Examples 1-3 and Comparative Examples 1-2, five rectangular vertical test specimens with a length of 200 mm and a width of 25 mm, and five rectangular horizontal test specimens with a length of 25 mm and a width of 200 mm were taken.

[0040] Then, using the Baylec method described in JIS L 1907(2010)7.1.2, the height to which the oil (Cosmo Gear SE150, manufactured by Cosmo Oil Lubricants Co., Ltd.) rose in the longitudinal and transverse test specimens (oil absorption height) was measured.

[0041] The oil absorption height was measured for five longitudinal and transverse test specimens, and the arithmetic mean was used to calculate the respective oil absorption heights.

[0042] Based on the measurement results, nonwoven fabrics (roll substrates) with an oil absorption height of less than 20 mm were evaluated as having insufficient wringability (△), nonwoven fabrics (roll substrates) with an oil absorption height of 20 mm or more but less than 30 mm were evaluated as having good wringability (〇), and nonwoven fabrics (roll substrates) with an oil absorption height of 30 mm or more were evaluated as having very good wringability (◎). These results are shown in Table 3.

[0043] (Durability test) Five circular test pieces with a diameter of 100 mm were taken from each of the nonwoven fabrics (roll base materials) used in Examples 1-3 and Comparative Examples 1-2.

[0044] Then, using a Taber abrasion tester (JIS K 7204), circular test specimens were subjected to friction under the following conditions, and the mass change rate was calculated from the mass before and after the test. The mass change rates of five test specimens were measured and their arithmetic mean was taken to obtain the mass change rate.

[0045] (1) Use of wear-resistant wheel H-22 (2) Number of wear cycles: 50 cycles (3) Rotation speed: 70 revolutions / minute (4) Load: 500g

[0046] Based on the measurement results, nonwoven fabrics (roll base materials) with a weight change rate of 5% or more were evaluated as having poor durability (△), nonwoven fabrics (roll base materials) with a weight change rate of 2% to less than 5% were evaluated as having good durability (〇), and nonwoven fabrics (roll base materials) with a weight change rate of less than 2% were evaluated as having very good durability (◎). These results are shown in Table 3.

[0047] As is clear from Table 3, the roll substrates of Examples 1 to 3, which consisted of fiber sheets containing 50-80 mass% unbleached cotton fibers, exhibited excellent moisture and oil extraction properties, enabling the production of rolls with superior extraction capabilities.

[0048] Furthermore, Table 3 shows that fiber sheets containing 50-80 mass% unbleached cotton fibers, that is, nonwoven fabrics (base materials for rolls) containing 50-20 mass% of abrasion-resistant fibers such as nylon fibers in addition to unbleached cotton fibers, exhibit superior durability, making it possible to produce rolls with superior durability.

[0049] [Table 3] [Industrial applicability]

[0050] Because the rolls of the present invention have excellent water and oil extraction capabilities, they can be suitably used as rolls for extracting water, oil, or chemicals in the manufacturing process of steel plates, non-ferrous metal plates, plastics, films, or resin plates, for example. [Explanation of Symbols]

[0051] 1 element 2 shafts

Claims

1. A base material for rolls, characterized by being made of a fiber sheet containing 50 to 80 mass% of unbleached cotton fibers.

2. The base material for rolls according to claim 1, characterized in that the constituent fibers of the fiber sheet are bonded and fixed with nitrile rubber.

3. A roll characterized in that a large number of roll base materials according to claim 1 or claim 2, which have a circular outer shape, are stacked on a shaft.

Images