Sheet manufacturing apparatus

Abstract

To provide sheet production equipment in which a portion where conveyance abnormity occurs can be easily removed, when the conveyance abnormity occurs.SOLUTION: Sheet production equipment is provided, comprising: a pressurization unit having a pressurization roller pressurizing material including fiber and a binding agent binding the fibers each other thereby forming the material into a continuous sheet; an individual sheet forming unit cutting the continuous sheet thereby forming the same into an individual sheet; a conveyance unit provided between the pressurization roller and the individual sheet forming unit, and conveying the continuous sheet formed by the pressurization unit to the individual sheet forming unit; and a segmentalization unit provided between the pressurization roller and the conveyance unit, and segmentalizing a portion of the continuous sheet where the conveyance abnormity occurs from the continuous sheet when a conveyance abnormity occurs in the conveyed continuous sheet.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a sheet manufacturing apparatus.

Background Art

[0002] Conventionally, in a sheet manufacturing apparatus, a so-called wet method has been adopted in which a raw material containing fibers is put into water, disintegrated mainly by mechanical action, and then re-pulped. Such a wet-type sheet manufacturing apparatus requires a large amount of water, resulting in a large-sized apparatus. Further, it is laborious to maintain the water treatment facility, and the energy required for the drying process increases.

[0003] Therefore, in order to miniaturize and save energy, a dry-type sheet manufacturing apparatus that does not use water as much as possible has been proposed. For example, in Patent Document 1, a defibrated product obtained by dry-defibrating paper without using water and a binder for binding fibers in the defibrated product are dry-mixed to form a web, and while transporting this web, it is heated and pressed with rollers, and then, it is cut into a predetermined length at a cutting section to manufacture a sheet. An apparatus is disclosed.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the sheet manufacturing apparatus described in Patent Document 1, it is in the state of a single continuous long sheet from being formed into a sheet by rollers until being cut into individual sheets at the cutting section. For this reason, for example, when a conveyance abnormality such as jamming occurs, it is difficult to eliminate the conveyance abnormality.

Means for Solving the Problems

[0006] The present invention has been made to solve the above-described problems and can be realized as follows.

[0007] The sheet manufacturing apparatus of the present invention includes a pressing unit having a pressing roller that presses a material containing fibers and a binder that binds the fibers together to form a continuous sheet, an individual sheet forming unit that cuts the continuous sheet to form individual sheets, a conveying unit provided between the pressing roller and the individual sheet forming unit, which conveys the continuous sheet formed by the pressing unit to the individual sheet forming unit, and a dividing unit provided between the pressing roller and the conveying unit, which divides a portion of the continuous sheet where a conveyance abnormality has occurred from the continuous sheet when a conveyance abnormality occurs in the conveyed continuous sheet.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Embodiment for Carrying Out the Invention

[0009] Hereinafter, the sheet manufacturing apparatus of the present invention will be described in detail based on the preferred embodiments shown in the accompanying drawings.

[0010] <Embodiment> FIG. 1 is a schematic side view showing the upstream side of an embodiment of the sheet manufacturing apparatus of the present invention. FIG. 2 is a schematic side view showing the downstream side of an embodiment of the sheet manufacturing apparatus of the present invention. FIG. 3 is a block diagram of the main part of the sheet manufacturing apparatus shown in FIGS. 1 and 2. FIGS. 4 to 7 are enlarged views of the portion indicated by the broken line in FIG. 2, and are diagrams for explaining the operation when a conveyance abnormality occurs. FIG. 8 is a flowchart for explaining the control operation executed by the control unit shown in FIG. 3.

[0011] In the following, for convenience of explanation, as shown in FIGS. 1, 2, 4 to 7, three axes orthogonal to each other are defined as the x-axis, y-axis, and z-axis. Also, the xy plane including the x-axis and y-axis is horizontal, and the z-axis is vertical. Further, the direction in which the arrow of each axis points is referred to as "+", and the opposite direction is referred to as "-". Also, the upper side of FIGS. 1, 2, 4 to 7 is referred to as "upper" or "above", and the lower side is referred to as "lower" or "below". Also, the left side of FIGS. 1, 2, 4 to 7 is referred to as the "upstream side", and the right side is referred to as the "downstream side".

[0012] As shown in FIGS. 1 and 2, the sheet manufacturing apparatus 100 includes a raw material supply unit 11, a crushing unit 12, a fiberizing unit 13, a sorting unit 14, a first web forming unit 15, a subdividing unit 16, a mixing unit 17, a loosening unit 18, a second web forming unit 19, a sheet forming unit 20, an individual sheet forming unit 21, a stock unit 22, a conveyance unit 25, a tension adjusting unit 26, a recovery unit 27, a control unit 28, a dividing unit 29, and an abnormality detection unit 30. Each part constituting the sheet manufacturing apparatus 100 is electrically connected to the control unit 28 shown in FIG. 3, and its operation is controlled by the control unit 28.

[0013] Further, as shown in FIG. 1, the sheet manufacturing apparatus 100 includes a humidifying unit 251, a humidifying unit 252, a humidifying unit 253, a humidifying unit 254, a humidifying unit 255, and a humidifying unit 256. In addition, the sheet manufacturing apparatus 100 includes a blower 173, a blower 261, a blower 262, and a blower 263.

[0014] In the sheet manufacturing apparatus 100, a raw material supply process, a crushing process, a fiberizing process, a sorting process, a first web forming process, a cutting process, a mixing process, a loosening process, a second web forming process, a sheet forming process, and a cutting process are executed in this order.

[0015] Hereinafter, the configuration of each part will be described. As shown in FIG. 1, the raw material supply unit 11 is a part that performs a raw material supply process of supplying the raw material M1 to the crushing unit 12. This raw material M1 is a sheet-like material made of a fiber-containing material containing cellulose fibers. The cellulose fibers may be any fibrous material mainly composed of cellulose as a compound, and may contain hemicellulose and lignin in addition to cellulose. Further, the form of the raw material M1 may be a woven fabric, a non-woven fabric, or the like. Further, the raw material M1 may be, for example, recycled paper obtained by defibrating and recycling waste paper, or Yupo paper (registered trademark) of synthetic paper, or may not be recycled paper. In the present embodiment, the raw material M1 is waste paper that has been used or is no longer needed.

[0016] The crushing unit 12 is a part that performs a crushing process of crushing the raw material M1 supplied from the raw material supply unit 11 in the air such as in the atmosphere. The crushing unit 12 has a pair of crushing blades 121 and a chute 122.

[0017] The pair of crushing blades 121 can crush, that is, cut, the raw material M1 between them by rotating in opposite directions to obtain crushed pieces M2. The shape and size of the crushed pieces M2 are preferably suitable for the fiberizing process in the fiberizing unit 13. For example, it is preferably a small piece with a side length of 100 mm or less, and more preferably a small piece with a side length of 10 mm or more and 70 mm or less.

[0018] The chute 122 is disposed below the pair of crushing blades 121 and has, for example, a funnel shape. This allows the chute 122 to receive the coarsely crushed pieces M2 that have been crushed by the crushing blades 121 and dropped.

[0019] In addition, above the chute 122, a humidifying section 251 is disposed adjacent to the pair of coarse crushing blades 121. The humidifying section 251 humidifies the coarsely crushed pieces M2 in the chute 122. This humidifying section 251 is configured as an evaporation type, particularly a hot air evaporation type, humidifier that has a moisture-containing filter (not shown) and supplies humidified air with increased humidity to the coarsely crushed pieces M2 by passing air through the filter. By supplying humidified air to the coarsely crushed pieces M2, it is possible to prevent the coarsely crushed pieces M2 from adhering to the chute 122, etc. due to static electricity.

[0020] The chute 122 is connected to the defibrating unit 13 via a pipe 241. The coarse crushed pieces M2 collected in the chute 122 pass through the pipe 241 and are transported to the defibrating unit 13.

[0021] The defibrating unit 13 is a section that performs a defibrating process in which the coarsely crushed pieces M2 are defibrated in the air, i.e., in a dry manner. The defibrating process in this defibrating unit 13 makes it possible to generate a defibrated material M3 from the coarsely crushed pieces M2. Here, "defibrating" refers to untangling the coarsely crushed pieces M2, which are made up of multiple fibers bound together, into individual fibers. This untangled material becomes the defibrated material M3. The shape of the defibrated material M3 is linear or band-like. The defibrated material M3 may also be present in a state where it is entangled with other pieces to form a mass, that is, in a state where it forms so-called "lumps."

[0022] In this embodiment, for example, the defibrating unit 13 is configured with an impeller mill having a rotor (not shown) that rotates at high speed and a liner located on the outer periphery of the rotor. The coarse fragments M2 that flow into the defibrating unit 13 are sandwiched between the rotor and the liner and defibrated.

[0023] In addition, the fiberizing unit 13 can generate an air flow, that is, an air current, from the crushing unit 12 toward the sorting unit 14 by the rotation of the rotor. Thereby, the crushed pieces M2 can be sucked from the pipe 241 into the fiberizing unit 13. Further, after the fiberizing process, the fiberized material M3 can be sent out to the sorting unit 14 via the pipe 242.

[0024] A blower 261 is installed in the middle of the pipe 242. The blower 261 is an air current generating device that generates an air current toward the sorting unit 14. Thereby, the sending-out of the fiberized material M3 to the sorting unit 14 is promoted.

[0025] The sorting unit 14 is a part that performs a sorting process of sorting the fiberized material M3 according to the length of the fibers. In the sorting unit 14, the fiberized material M3 is sorted into a first sorted material M4-1 and a second sorted material M4-2 that is larger than the first sorted material M4-1. The first sorted material M4-1 has a size suitable for the subsequent production of the sheet S. Its average length is preferably 1 μm or more and 30 μm or less. On the other hand, the second sorted material M4-2 includes, for example, those with insufficient fiberization or those in which the fiberized fibers are excessively aggregated.

[0026] The sorting unit 14 has a drum unit 141 and a housing unit 142 that houses the drum unit 141.

[0027] The drum unit 141 is composed of a cylindrical net body and is a sieve that rotates around its central axis. The fiberized material M3 flows into the drum unit 141. Then, as the drum unit 141 rotates, the fiberized material M3 smaller than the mesh opening of the net is sorted as the first sorted material M4-1, and the fiberized material M3 larger than or equal to the mesh opening is sorted as the second sorted material M4-2.

[0028] The first sorted material M4-1 falls from the drum unit 141. On the other hand, the second sorted material M4-2 is sent to a pipe 243 connected to the drum part 141. The pipe 243 is connected to the pipe 241 on the side opposite to the drum part 141, that is, the upstream side. The second sorted material M4-2 that has passed through this pipe 243 merges with the crushed pieces M2 in the pipe 241 and flows into the defibrating part 13 together with the crushed pieces M2. As a result, the second sorted material M4-2 is returned to the defibrating part 13 and is defibrated together with the crushed pieces M2.

[0029] In addition, the first sorted material M4-1 discharged from the drum part 141 falls while being dispersed in the air and heads toward the first web forming part 15 located below the drum part 141. The first web forming part 15 is a part that performs a first web forming process of forming a first web M5 from the first sorted material M4-1. The first web forming part 15 has a mesh belt 151, three tension rollers 152, and a suction part 153.

[0030] The mesh belt 151 is an endless belt on which the first sorted material M4-1 accumulates. This mesh belt 151 is wound around three tension rollers 152. Then, by the rotational drive of the tension rollers 152, the first sorted material M4-1 on the mesh belt 151 is conveyed to the downstream side.

[0031] The first sorted material M4-1 has a size larger than the mesh opening of the mesh belt 151. As a result, the passage of the first sorted material M4-1 through the mesh belt 151 is restricted, and thus it can accumulate on the mesh belt 151. In addition, while the first sorted material M4-1 accumulates on the mesh belt 151, it is conveyed to the downstream side together with the mesh belt 151, and thus is formed as a layered first web M5.

[0032] In addition, there is a possibility that, for example, dust and dirt are mixed in the first sorted material M4-1. Dust and dirt may be generated, for example, by crushing and defibrating. And such dust and dirt will be collected by a collection part 27 described later.

[0033] The suction part 153 is a suction mechanism that sucks air from below the mesh belt 151. Thereby, dust and dirt that have passed through the mesh belt 151 can be sucked together with the air.

[0034] Further, the suction part 153 is connected to the collection part 27 via a pipe 244. Dust and dirt sucked by the suction part 153 are collected by the collection part 27.

[0035] A pipe 245 is further connected to the collection part 27. Also, a blower 262 is installed in the middle of the pipe 245. By the operation of this blower 262, suction force can be generated in the suction part 153. Thereby, the formation of the first web M5 on the mesh belt 151 is promoted. This first web M5 is one from which dust and dirt etc. have been removed. Also, dust and dirt reach the collection part 27 through the pipe 244 by the operation of the blower 262.

[0036] The housing part 142 is connected to the humidifying part 252. The humidifying part 252 is composed of a vaporizing type humidifier similar to the humidifying part 251. Thereby, humidified air is supplied into the housing part 142. By this humidified air, the first sorted material M4 - 1 can be humidified, and thus it is also possible to suppress the first sorted material M4 - 1 from adhering to the inner wall of the housing part 142 by electrostatic force.

[0037] A humidifying part 255 is arranged on the downstream side of the sorting part 14. The humidifying part 255 is composed of an ultrasonic humidifier that sprays water. Thereby, moisture can be supplied to the first web M5, and thus the moisture content of the first web M5 is adjusted. By this adjustment, it is possible to suppress the adsorption of the first web M5 to the mesh belt 151 by electrostatic force. Thereby, the first web M5 can be easily peeled off from the mesh belt 151 at the position where the mesh belt 151 is folded back by the tensioning roller 152.

[0038] On the downstream side of the humidifying section 255, a dividing section 16 is arranged. The dividing section 16 is a part that performs a dividing process of dividing the first web M5 peeled from the mesh belt 151. The dividing section 16 has a rotatably supported propeller 161 and a housing section 162 that houses the propeller 161. Then, the rotating propeller 161 can divide the first web M5. The divided first web M5 becomes the divided body M6. Also, the divided body M6 descends inside the housing section 162.

[0039] The housing section 162 is connected to the humidifying section 253. The humidifying section 253 is composed of a vaporizing type humidifier similar to the humidifying section 251. Thereby, humidified air is supplied into the housing section 162. It is also possible to suppress the divided body M6 from adhering to the inner wall of the propeller 161 and the housing section 162 due to electrostatic force by this humidified air.

[0040] On the downstream side of the dividing section 16, a mixing section 17 is arranged. The mixing section 17 is a part that performs a mixing process of mixing the divided body M6 and the binder P1. This mixing section 17 has a binder supply section 171, a pipe 172, and a blower 173.

[0041] The pipe 172 connects the housing section 162 of the dividing section 16 and the housing section 182 of the loosening section 18, and is a flow path through which the mixture M7 of the divided body M6 and the binder P1 passes.

[0042] In the middle of the pipe 172, the binder supply section 171 is connected. The binder supply section 171 has a screw feeder 174. By rotationally driving this screw feeder 174, the binder P1 can be supplied to the pipe 172 as powder or particles. The binder P1 supplied to the pipe 172 is mixed with the divided body M6 to become the mixture M7.

[0043] Note that the binder P1 binds fibers to each other in a subsequent process. For example, thermoplastic resins, curable resins, starch, dextrin, glycogen, amylose, hyaluronic acid, kudzu, konjac, katakuri starch, etherified starch, esterified starch, natural gum paste (etherified tamarind gum, etherified locust bean gum, etherified guar gum, acacia arabica-based gum), fiber-derived paste (etherified carboxymethyl cellulose, hydroxyethyl cellulose), seaweeds (sodium alginate, agar), animal proteins (collagen, gelatin, hydrolyzed collagen, sericin), etc. can be used, but it is preferable to use a thermoplastic resin. Examples of thermoplastic resins include polyolefins such as AS resin, ABS resin, polyethylene, polypropylene, ethylene-vinyl acetate copolymer (EVA), modified polyolefins, acrylic resins such as polymethyl methacrylate, polyvinyl chloride, polystyrene, polyesters such as polyethylene terephthalate and polybutylene terephthalate, polyamides such as nylon 6, nylon 46, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon 6-12, nylon 6-66, polyphenylene ether, polyacetal, polyether, polyphenylene oxide, polyether ether ketone, polycarbonate, polyphenylene sulfide, thermoplastic polyimide, polyetherimide, liquid crystal polymers such as aromatic polyesters, and various thermoplastic elastomers such as styrene-based, polyolefin-based, polyvinyl chloride-based, polyurethane-based, polyester-based, polyamide-based, polybutadiene-based, trans-polyisoprene-based, fluororubber-based, chlorinated polyethylene-based, etc. One or more selected from these can be used in combination. Preferably, as the thermoplastic resin, a polyester or one containing the same is used.

[0044] In addition to the binder P1, what is supplied from the binder supply unit 171 may include, for example, a colorant for coloring fibers, an aggregation inhibitor for suppressing the aggregation of fibers or the binder P1, a flame retardant for making fibers and the like less flammable, a paper strength enhancer for enhancing the paper strength of the sheet S, and the like. Alternatively, a composite in which these are previously included in the binder P1 may be supplied from the binder supply unit 171.

[0045] Also, a blower 173 is installed in the middle of the pipe 172 on the downstream side of the binder supply unit 171. By the action of the rotating part such as the blades of the blower 173, the fine particles M6 and the binder P1 are mixed. Further, the blower 173 can generate an air flow toward the loosening part 18. By this air flow, the fine particles M6 and the binder P1 can be stirred in the pipe 172. As a result, the mixture M7 can flow into the loosening part 18 in a state where the fine particles M6 and the binder P1 are uniformly dispersed. Also, the fine particles M6 in the mixture M7 are loosened in the process of passing through the pipe 172 and become finer fibrous.

[0046] The loosening part 18 is a part that performs a loosening process of loosening the fibers intertwined with each other in the mixture M7. The loosening part 18 has a drum part 181 and a housing part 182 that houses the drum part 181.

[0047] The drum part 181 is composed of a cylindrical net body and is a sieve that rotates around its central axis. The mixture M7 flows into the drum part 181. Then, when the drum part 181 rotates, fibers and the like smaller than the mesh opening of the net in the mixture M7 can pass through the drum part 181. At that time, the mixture M7 is loosened.

[0048] The housing part 182 is connected to the humidifying part 254. The humidifying part 254 is composed of a vaporizing type humidifier similar to the humidifying part 251. Thereby, humidified air is supplied into the housing part 182. With this humidified air, the inside of the housing part 182 can be humidified, and thus it is also possible to suppress the mixture M7 from adhering to the inner wall of the housing part 182 by electrostatic force.

[0049] Also, the mixture M7 loosened by the drum part 181 falls while being dispersed in the air and heads toward the second web forming part 19 located below the drum part 181. The second web forming part 19 is a part that performs a second web forming process of forming the second web M8 from the mixture M7. The second web forming part 19 includes a mesh belt 191, a stretching roller 192, and a suction part 193.

[0050] The mesh belt 191 is an endless belt on which the mixture M7 accumulates. This mesh belt 191 is wound around four stretching rollers 192. Then, by the rotational drive of the stretching roller 192, the mixture M7 on the mesh belt 191 is conveyed to the downstream side.

[0051] Also, most of the mixture M7 on the mesh belt 191 is larger than the mesh opening of the mesh belt 191. Thereby, the mixture M7 is restricted from passing through the mesh belt 191, and thus can accumulate on the mesh belt 191. Also, while the mixture M7 accumulates on the mesh belt 191, it is conveyed to the downstream side together with the mesh belt 191, and thus is formed as a layered second web M8.

[0052] The suction part 193 is a suction mechanism that sucks air from below the mesh belt 191. Thereby, the mixture M7 can be sucked onto the mesh belt 191, and thus the accumulation of the mixture M7 on the mesh belt 191 is promoted.

[0053] A pipe 246 is connected to the suction part 193. Also, a blower 263 is installed in the middle of this pipe 246. By operating this blower 263, a suction force can be generated in the suction part 193.

[0054] A humidifying part 256 is arranged on the downstream side of the loosening part 18. The humidifying part 256 is composed of an ultrasonic humidifier similar to the humidifying part 255. Thereby, moisture can be supplied to the second web M8, and thus the moisture content of the second web M8 is adjusted. By this adjustment, adsorption of the second web M8 to the mesh belt 191 by electrostatic force can be suppressed. As a result, the second web M8 can be easily peeled off from the mesh belt 191 at the position where the mesh belt 191 is folded back by the tensioning roller 192.

[0055] Note that the total amount of moisture added to the humidifying parts 251 to 256 is preferably, for example, 0.5 parts by mass or more and 20 parts by mass or less with respect to 100 parts by mass of the material before humidification.

[0056] On the downstream side of the second web forming part 19, as shown in FIG. 2, a sheet forming part 20 is arranged. The sheet forming part 20 is a part that performs a sheet forming process of forming a continuous sheet S0 from the second web M8. This sheet forming part 20 has a pressing part 201 and a heating part 202.

[0057] The pressing part 201 has a pair of pressing rollers 203 and can press the second web M8 between the pressing rollers 203 without heating it. Thereby, the density of the second web M8 is increased. Note that the degree of heating at this time is preferably, for example, such that the binder P1 is not melted. Then, this second web M8 is conveyed toward the heating part 202. Note that one of the pair of pressing rollers 203 is a driving main roller driven by the operation of a motor (not shown), and the other is a driven roller.

[0058] The heating unit 202 has a pair of heating rollers 204, and can heat and press the second web M8 between the heating rollers 204. By this heating and pressing, in the second web M8, the binder P1 melts, and the fibers are bonded to each other through the melted binder P1. Thereby, a single continuous sheet S0 is formed. Then, this continuous sheet S0 is conveyed toward the individual sheet forming unit 21. Note that one of the pair of heating rollers 204 is a driving main roller driven by the operation of a motor (not shown), and the other is a driven roller.

[0059] These pressure unit 201 and heating unit 202 constitute a forming roller group for forming a web containing a material including fibers. Note that the heating unit 202 may be omitted. Also, the pressure roller 203 of the pressure unit 201 may have a function of heating.

[0060] An individual sheet forming unit 21 is disposed on the downstream side of the sheet forming unit 20. The individual sheet forming unit 21 is a part that performs a cutting process of cutting the continuous sheet S0 to form the sheet S which is an individual sheet. The individual sheet forming unit 21 has a first cutter 211 and a second cutter 212 installed on the downstream side of the first cutter 211.

[0061] The first cutter 211 cuts the continuous sheet S0 in a direction intersecting the conveyance direction of the continuous sheet S0, particularly in a direction perpendicular thereto. The first cutter 211 has a pair of rollers 211A installed so as to be separated from each other in the thickness direction, that is, in the z-axis direction of the conveyed sheet S, and blades 211B provided so as to protrude from the outer peripheral portions of the respective rollers 211A. The blades 211B are provided so as to extend in the axial direction of each roller 211A.

[0062] As shown in FIG. 3, the first cutter 211 is electrically connected to the control unit 28 and its operation is controlled. The first cutter 211 rotates in the direction of the arrow in FIG. 2, and at this time, the blades 211B come into contact with each other. As a result, the passing continuous sheet S0 is cut. Also, by adjusting the rotational speed of each first cutter 211, the length of the sheet S in the x-axis direction can be adjusted.

[0063] The second cutter 212 cuts the sheet S in a direction parallel to the conveyance direction of the sheet S on the downstream side of the first cutter 211. The second cutter 212 is composed of four disk-shaped rotating blades 212A and rotating blades 212B. The rotating blades 212A and the rotating blades 212B are arranged to face each other through the sheet S being conveyed, that is, through the conveyance path 238. By the contact of the rotating blades 212A and the rotating blades 212B, the conveyed sheet S can be cut.

[0064] Also, a pair of the rotating blades 212A and the rotating blades 212B are arranged in a pair in the width direction of the sheet S, that is, in the y-axis direction. Thereby, unnecessary portions at both side ends of the sheet S, that is, the ends in the +y-axis direction and the -y-axis direction are removed to adjust the width of the sheet S, and the cut and removed portions are called so-called "ears".

[0065] Also, in each second cutter 212, the separation distance between the rotating blades 212A and the rotating blades 212B facing each other in the y-axis direction can be adjusted, and by adjusting this separation distance, the length of the sheet S in the y-axis direction can be adjusted.

[0066] By such cutting with the first cutter 211 and the second cutter 212, a sheet S having a desired shape and size is obtained. Then, this sheet S is further conveyed downstream and accumulated in the stock unit 22.

[0067] The discharge mechanism 23 has a function of conveying the formed sheet S to the stock unit 22. The discharge mechanism 23 includes a post-cutting roller 232, an intermediate roller 233, a first paper discharge roller 234, and a second paper discharge roller 235. The intermediate roller 233, the first paper discharge roller 234, and the second paper discharge roller 235 are arranged in this order on the upstream side in the conveyance direction of the sheet S, that is, on the -x axis side.

[0068] Also, a pair of the post-cutting roller 232, the intermediate roller 233, the first paper discharge roller 234, and the second paper discharge roller 235 are arranged in pairs via a conveyance path 238, respectively.

[0069] The post-cutting roller 232 is installed in a pair between the first cutter 211 and the second cutter 212 and via the conveyance path 238 in the z-axis direction. The post-cutting roller 232 contributes to the conveyance of the continuous sheet S0 before being cut by the first cutter 211 until it is cut and delivered to the intermediate roller 233. With the sheet S held by each post-cutting roller 232, when each post-cutting roller 232 rotates in the direction of the arrow in FIG. 2, the cut sheet S can be conveyed in the +x axis direction.

[0070] One of the pair of post-cutting rollers 232 is a driving main roller driven by the operation of a motor (not shown), and the other is a driven roller. As shown in FIG. 3, the post-cutting roller 232 that is the main roller is electrically connected to the control unit 28, and its operation is controlled.

[0071] The intermediate roller 233 is arranged in a pair via the conveyance path 238 in the z-axis direction on the downstream side of the second cutter 212, that is, on the +x axis side. The intermediate roller 233 particularly contributes to the conveyance of the sheet S after the "ears" are cut. With the sheet S held by each intermediate roller 233, when each intermediate roller 233 rotates in the direction of the arrow in FIG. 2, the sheet S after the "ears" are cut can be conveyed in the +x axis direction.

[0072] One of the pair of intermediate rollers 233 is a driving roller driven by the operation of a motor (not shown), and the other is a driven roller. As shown in FIG. 3, the intermediate roller 233, which is the driving roller, is electrically connected to the control unit 28, and its operation is controlled.

[0073] The first paper discharge roller 234 is arranged in a pair on the downstream side of the intermediate roller 233, that is, on the +x-axis side, via the conveyance path 238 in the z-axis direction. The first paper discharge roller 234 particularly contributes to conveying the sheet S to the stock unit 22. With the sheet S being sandwiched by each first paper discharge roller 234, the sheet S can be conveyed in the +x-axis direction by each first paper discharge roller 234 rotating in the direction of the arrow in FIG. 2.

[0074] One of the pair of first paper discharge rollers 234 is a driving roller driven by the operation of a motor (not shown), and the other is a driven roller. As shown in FIG. 3, the first paper discharge roller 234, which is the driving roller, is electrically connected to the control unit 28, and its operation is controlled.

[0075] The second paper discharge roller 235 is arranged in a pair on the downstream side of the first paper discharge roller 234, that is, on the +x-axis side, via the conveyance path 238 in the z-axis direction. The second paper discharge roller 235 particularly contributes to conveying the sheet S to the stock unit 22. With the sheet S being sandwiched by each second paper discharge roller 235, the sheet S can be conveyed to the stock unit 22 by each second paper discharge roller 235 rotating in the direction of the arrow in FIG. 2.

[0076] One of the pair of second paper discharge rollers 235 is a driving roller driven by the operation of a motor (not shown), and the other is a driven roller. As shown in FIG. 3, the second paper discharge roller 235, which is the driving roller, is electrically connected to the control unit 28, and its operation is controlled.

[0077] After such cutting, the roller 232, the intermediate roller 233, the first paper discharge roller 234, and the second paper discharge roller 235 have their rotation speeds appropriately adjusted by the control unit 28.

[0078] The conveying unit 25 is provided between the heating roller 204 and the individual sheet forming unit 21, and conveys the continuous sheet S0 formed by the sheet forming unit 20 to the individual sheet forming unit 21. In the present embodiment, the conveying unit 25 is constituted by a pair of conveying rollers 251A. However, the present invention is not limited thereto, and the conveying unit 25 may be configured to perform conveying by, for example, a rotating endless belt.

[0079] The pair of conveying rollers 251A are arranged via the conveying path 238 in the z-axis direction. With the sheet S being sandwiched by the conveying rollers 251A, when each conveying roller 251A rotates in the direction of the arrow in FIG. 2, the continuous sheet S0 can be conveyed to the individual sheet forming unit 21.

[0080] One of the pair of conveying rollers 251A is a driving roller driven by the operation of a motor (not shown), and the other is a driven roller. As shown in FIG. 3, the conveying roller 251A which is the driving roller is electrically connected to the control unit 28, and its operation is controlled.

[0081] The tension adjusting unit 26 has a function of adjusting the tension applied to the continuous sheet S0. The tension adjusting unit 26 is installed between the cutting unit 29 and the conveying roller 251A, and on the upper surface side of the sheet S during conveyance, that is, on the +z-axis side. Note that the tension adjusting unit 26 may be installed on the lower surface side of the sheet S, that is, on the -z-axis side.

[0082] In this embodiment, the tension adjustment unit 26 includes a roller 261A, a moving mechanism 262A such as a motor or a solenoid, and a tension detection unit 263A. By the operation of the moving mechanism 262A, the roller 261A approaches and separates from the continuous sheet S0 during movement. When the roller 261A is pressed, the tension is increased, and when the roller 261A retracts from the continuous sheet S0, the tension of the continuous sheet S0 is relaxed. Further, as shown in FIG. 3, the moving mechanism 262A is electrically connected to the control unit 28, and its operation is controlled.

[0083] In this embodiment, the tension detection unit 263A is a torque sensor connected to the roller 261A. The tension detection unit 263A is electrically connected to the control unit 28, and information regarding the torque value detected by the tension detection unit 263A is transmitted to the control unit 28. Then, the control unit 28 estimates the tension from the information regarding the torque value.

[0084] However, it is not limited to this configuration, and the tension detection unit 263A may be configured to directly measure the tension in contact with the continuous sheet S, for example.

[0085] In this way, the sheet manufacturing apparatus 100 includes a tension adjustment unit 26 that adjusts the tension of the continuous sheet S0 between the pressing unit 201 and the conveying unit 25. Thereby, it is possible to reduce the occurrence of conveyance abnormalities such as jamming by adjusting the tension of the continuous sheet S0. Further, when a conveyance abnormality occurs and the continuous sheet S0 is cut, the tension of the continuous sheet S0 can be adjusted to perform the cutting well.

[0086] Further, when the continuous sheet S0 is cut, the tension adjustment unit 26 reduces the tension of the continuous sheet S0. Thereby, it is possible to prevent excessive tension from cutting the continuous sheet S0. Therefore, the cut end can be made into a desired shape. Further, it is possible to prevent or suppress the end of the continuous sheet S0 from moving to an unexpected position when cutting.

[0087] Further, the tension adjusting unit 26 is provided between the dividing unit 29 and the conveying unit 25, and has a roller 261A that can approach and separate from the continuous sheet S0. Thereby, the tension of the continuous sheet S0 can be adjusted better.

[0088] The dividing unit 29 is provided between the pressing roller 203 and the conveying unit 25, and has a function of dividing a portion of the continuous sheet S0 where a conveying abnormality has occurred from the continuous sheet when a conveying abnormality occurs in the continuously conveyed continuous sheet S0.

[0089] The dividing unit 29 has a pair of rollers 291 that are spaced apart from each other through the continuous sheet S0 to be conveyed in the thickness direction, that is, the z-axis direction, and cutting blades 292 provided to protrude from the outer peripheral portions of the respective rollers 291. The cutting blades 292 are provided to extend in the axial direction of each roller 291.

[0090] The roller 291 rotates in the direction of the arrow in FIG. 2, and at this time, the cutting blades 292 come into contact with each other. Thereby, the continuous sheet S0 passing therethrough is cut. As shown in FIG. 3, the dividing unit 29 is electrically connected to the control unit 28, and its operation is controlled. That is, a motor (not shown) connected to each roller 291 is electrically connected to the control unit 28, and its operation is controlled.

[0091] Note that the configuration of the dividing unit 29 is not limited to the above, and for example, it may be a configuration that cuts while moving in a direction intersecting the conveying direction of the continuous sheet S0, or a configuration that cuts by moving in the z-axis direction. Further, it may be a configuration that divides the continuous sheet S0 by irradiating an energy beam such as a laser.

[0092] The abnormality detection unit 30 has a function of detecting that a conveyance abnormality has occurred in the continuously conveyed continuous sheet S0. The abnormality detection unit 30 is installed between the tension adjustment unit 26 and the conveyance unit 25. In the present embodiment, the abnormality detection unit 30 is an optical sensor. The abnormality detection unit 30 is installed at a position deviated from the conveyance path 238 of the continuous sheet S0, and in the illustrated configuration, it is installed on the +z-axis side with respect to the conveyance path 238. Therefore, when the continuous sheet S0 deviates from the conveyance path 238, this can be detected. Further, the abnormality detection unit 30 is electrically connected to the control unit 28, and the information detected by the abnormality detection unit 30, that is, the information that a conveyance abnormality has occurred, is transmitted to the control unit 28. The conveyance abnormality means that the continuous sheet S0 deviates from the conveyance path 238, and specifically, it means jamming, deflection, tearing, etc.

[0093] As described above, the sheet manufacturing apparatus 100 includes the abnormality detection unit 30 which is a detection unit for detecting a conveyance abnormality of the continuous sheet S0. Thereby, it is possible to detect that a conveyance abnormality has occurred in the continuous sheet S0. Note that the abnormality detection unit 30 may be omitted and the configuration may be such that an operator visually confirms. In this case, when the operator confirms a conveyance abnormality, the cutting unit 29 is operated.

[0094] As shown in FIG. 3, the control unit 28 has a CPU (Central Processing Unit) 281 and a storage unit 282. The CPU 281 can perform various determinations, various commands, etc., for example.

[0095] The storage unit 282 stores various programs such as a program for manufacturing the sheet S, for example.

[0096] This control unit 28 may be built in the sheet manufacturing apparatus 100, or may be provided in an external device such as an external computer. Further, the external device may be connected to the sheet manufacturing apparatus 100 via a cable or the like, may be wirelessly communicated, or may be connected to the sheet manufacturing apparatus 100 via a network such as the Internet, for example.

[0097] Further, the CPU 281 and the storage unit 282 may be integrated, for example, and configured as one unit. Or, the CPU 281 may be built into the sheet manufacturing apparatus 100, and the storage unit 282 may be provided in an external device such as an external computer. Or, the storage unit 282 may be built into the sheet manufacturing apparatus 100, and the CPU 281 may be provided in an external device such as an external computer.

[0098] In such a sheet manufacturing apparatus 100, when a conveyance abnormality occurs as shown in FIG. 4, the abnormality detection unit 30 detects it. Then, as shown in FIG. 5, the conveyance of the continuous sheet S0 is stopped, and the tension adjustment unit 26 relaxes the tension of the continuous sheet S0 to a tension suitable for cutting. Next, as shown in FIG. 6, the roller 291 of the cutting unit 29 is rotated, and the continuous sheet S0 is cut by the cutting blade 292. Then, as shown in FIG. 7, the portion X cut from the continuous sheet S0 is removed.

[0099] According to such a configuration, the portion X where the conveyance abnormality has occurred can be cut from the continuous sheet S0, and this portion X can be removed. In particular, the continuous sheet S0 is a continuous and relatively long sheet. Conventionally, when a conveyance abnormality occurred, the apparatus was once stopped, and after identifying the abnormal location, the operator cut and removed the abnormal portion. In the present invention, since the portion including the portion X where the conveyance abnormality has occurred by the cutting unit 29, that is, the portion of the continuous sheet S0 from the position where the cutting unit 29 cuts to the position where the first cutter 211 cuts is cut, the conveyance abnormality can be eliminated by a simple method of removing that portion.

[0100] Note that the configuration is not limited to the control unit 28 controlling the operation of the cutting unit 29. For example, a configuration in which an operator manually operates the cutting unit 29 may be used.

[0101] As described above, the sheet manufacturing apparatus 100 includes a pressing unit 201 having a pressing roller 203 that presses a second web M8, which is a material including fibers and a binder P1 that binds the fibers together, to form a continuous sheet S0; an individual sheet forming unit 21 that cuts the continuous sheet S0 to form individual sheets S; a conveying unit 25 that is provided between the pressing roller 203 and the individual sheet forming unit 21 and conveys the continuous sheet S0 formed by the pressing unit 201 to the individual sheet forming unit 21; and a dividing unit 29 that is provided between the pressing roller 203 and the conveying unit 25 and divides a portion X where a conveyance abnormality has occurred in the conveyed continuous sheet S0 from the continuous sheet S0 when a conveyance abnormality occurs in the continuous sheet S0 being conveyed. Thereby, when a conveyance abnormality occurs, a portion of the continuous sheet S0 from the position where the dividing unit 29 divides to the position where the individual sheet forming unit 21 cuts can be divided, and the portion where the conveyance abnormality has occurred, portion X, can be removed by a simple method of removing that portion.

[0102] Further, the conveying unit 25 has a pair of conveying rollers 251A. When the conveyance abnormality is a jam that occurs in the pair of conveying rollers 251A, it is particularly difficult to resolve in the conventional case, so the effects of the present invention can be obtained more remarkably.

[0103] Also, the dividing unit 29 divides a portion of the continuous sheet S0 that is downstream of the pressing roller 203 and upstream of the portion X where the conveyance abnormality has occurred in a direction intersecting the conveyance direction of the continuous sheet S0. Thereby, the divided sheet will include portion X, and the portion X where the conveyance abnormality has occurred can be removed more reliably.

[0104] Also, the dividing unit 29 has a cutting blade 292 that extends in a direction intersecting the conveyance direction of the continuous sheet S0. Thereby, the continuous sheet S0 can be easily cut in the width direction, and the division can be performed promptly.

[0105] Next, the control operation performed by the control unit 28 will be described with reference to the flowchart shown in FIG. 8.

[0106] First, in step S101, start sheet manufacturing. That is, drive each part of the sheet manufacturing apparatus 100 to start manufacturing the sheet S.

[0107] Next, in step S102, determine whether a conveyance abnormality has been detected. The determination in this step is made based on the detection result of the abnormality detection unit 30.

[0108] If it is determined in step S102 that a conveyance abnormality has occurred, then in step S103, stop the conveyance. That is, stop the operation of each part of the sheet manufacturing apparatus 100, particularly the conveyance unit 25. At this time, it is preferable to notify the fact that a conveyance abnormality has occurred by a notification unit (not shown). On the other hand, if it is determined in step S102 that no conveyance abnormality has occurred, proceed to step S108.

[0109] Next, in step S104, adjust the tension of the continuous sheet S0. This step is executed, for example, as shown in FIG. 5, by separating the roller 261A of the tension adjustment unit 26 from the continuous sheet S0.

[0110] Next, in step S105, operate the cutting unit 29 to cut the portion X where the conveyance abnormality has occurred from the continuous sheet S0. Then, the operator removes the sheet including the cut portion X.

[0111] Next, in step S106, determine whether a restart instruction has been given. The determination in this step is made based on, for example, whether the operator has pressed a restart button (not shown). If it is determined in step S106 that a restart instruction has been given, then in step S107, restart the sheet manufacturing. On the other hand, if it is determined in step S106 that no restart instruction has been given, wait until a restart instruction is input.

[0112] Next, in step S108, it is determined whether the sheet manufacturing has been completed. The determination in this step is made, for example, based on whether the number of manufactured sheets S has reached a predetermined number. If it is determined in step S108 that the sheet manufacturing has been completed, the execution of the program is terminated. On the other hand, if it is determined in step S108 that the sheet manufacturing has not been completed, the process returns to step S102 and the subsequent steps are sequentially executed.

[0113] As described above, the sheet manufacturing apparatus 100 includes a control unit 28 that controls the operation of the cutting unit 29 based on the detection result of the abnormality detection unit 30, which is a detection unit. Thereby, when a conveyance abnormality occurs, it is possible to automatically cut the portion of the continuous sheet S0 from the position where the cutting unit 29 cuts to the position where the individual sheet forming unit 21 cuts. Therefore, the portion X where the conveyance abnormality has occurred can be removed by a simple method of removing that portion.

[0114] As described above, the sheet manufacturing apparatus of the present invention has been described with respect to the illustrated embodiment. However, the present invention is not limited thereto, and each part constituting the sheet manufacturing apparatus can be replaced with any configuration that can exhibit the same function. Further, any component may be added.

Explanation of Reference Numerals

[0115] 11…Raw material supply section, 12…Crushing section, 13…Fiber separation section, 14…Sorting section, 15…First web forming section, 16…Subdivision section, 17…Mixing section, 18…Loosening section, 19…Second web forming section, 20…Sheet forming section, 21…Individual sheet forming section, 22…Stock section, 23…Discharge mechanism, 25…Conveying section, 26…Tension adjustment section, 27…Recovery section, 28…Control section, 29…Cutting section, 30…Abnormality detection section, 100…Sheet manufacturing apparatus, 121…Crushing blade, 122…Shoot, 141…Drum section, 142…Housing section, 151…Mesh belt, 152…Tensioning roller, 153…Suction section, 161…Propeller, 162…Housing section, 171…Binder supply section, 172…Pipe, 173…Blower, 174…Screw feeder, 181…Drum section, 182…Housing section, 191…Mesh belt, 192…Tensioning roller, 193…Suction section, 201…Pressing section, 202…Heating section, 203…Pressing roller, 204…Heating roller, 211…First cutter, 211A…Roller, 211B…Blade, 212…Second cutter, 212A…Rotating blade, 212B…Rotating blade, 232…Post-cutting roller, 233…Intermediate roller, 234…First paper discharge roller, 235…Second paper discharge roller, 238…Conveying path, 241…Pipe, 242…Pipe, 243…Pipe, 244…Pipe, 245…Pipe, 246…Pipe, 251…Humidifying section, 251A…Conveying roller, 252…Humidifying section, 253…Humidifying section, 254…Humidifying section, 255…Humidifying section, 256…Humidifying section, 261…Blower, 261A…Roller, 262…Blower, 262A…Moving mechanism, 263…Blower, 263A…Tension detection section, 281…CPU, 282…Memory section, 291…Roller, 292…Cutting blade, M1…Raw material, M2…Crushed pieces, M3…Fiber-separated material, M4-1…First sorted material, M4-2…Second sorted material, M5…First web, M6…Subdivided body, M7…Mixture, M8…Second web, S…Sheet, S0…Continuous sheet, X…Portion, P1…Binder

Claims

1. A pressing unit having a pressing roller for pressing a material including fibers and a binder for binding the fibers together to form a continuous sheet; An individual sheet forming unit for cutting the continuous sheet into individual sheets; A conveying unit provided between the pressing roller and the individual sheet forming unit for conveying the continuous sheet formed by the pressing unit to the individual sheet forming unit; An abnormality detection unit provided between the pressing roller and the conveying unit for detecting that a conveyance abnormality has occurred in the continuously conveyed sheet; A dividing unit provided between the pressing roller and the abnormality detection unit for dividing a portion of the continuous sheet in which a conveyance abnormality has occurred from the continuous sheet in response to the abnormality detection unit detecting that a conveyance abnormality has occurred in the continuously conveyed sheet; A control unit for controlling the operation of the dividing unit, wherein the sheet manufacturing apparatus is characterized by comprising the above components.

2. The sheet manufacturing apparatus according to claim 1, wherein the dividing unit divides a portion of the continuous sheet that is downstream of the pressing roller and upstream of the portion where the conveyance abnormality has occurred in a direction intersecting the conveyance direction of the continuous sheet.

3. The sheet manufacturing apparatus according to claim 1 or 2, wherein the dividing unit has a cutting blade extending in a direction intersecting the conveyance direction of the continuous sheet.

4. The sheet manufacturing apparatus according to any one of claims 1 to 3, further comprising a tension adjusting unit for adjusting the tension of the continuous sheet between the pressing unit and the conveying unit.

5. The sheet manufacturing apparatus according to claim 4, wherein the tension adjusting unit reduces the tension of the continuous sheet when dividing the continuous sheet.

6. The sheet manufacturing apparatus according to claim 5, wherein the tension adjusting unit is provided between the dividing unit and the conveying unit and has a roller that can approach and separate from the continuous sheet.

7. The conveying unit has a pair of conveying rollers, The sheet manufacturing apparatus according to any one of claims 1 to 6, wherein the conveyance abnormality is jamming occurring in the pair of conveying rollers.

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