Breathable product manufacturing method and manufacturing device

Abstract

To provide a method and an apparatus for manufacturing an air permeable product which can provide an air permeable product having an adhesive layer having an appropriate layer thickness in a part exposed to a surface of an air permeable base material.SOLUTION: A method for manufacturing an air permeable product performs the steps of: preparing an air permeable base material (S1) having a gap on at least one surface side; and preparing an adhesive layer (N) for being formed in a part on the one surface side, and controlling hardness of the adhesive layer (N) so that only a part of the adhesive layer (N) enters into a gap of the air permeable base material (S1). A range of the adhesive layer (N) entering into the air permeable base material (S1) can be controlled by pressing the adhesive layer (N) whose hardness is controlled against the air permeable base material (S1). Thereby, an air permeable product (F) whose layer thickness is made appropriate in a part exposed to the surface of the adhesive layer (N) can be obtained. A part of the adhesive layer (N) enters into the gap of the air permeable base material (S1), thereby both of them are integrated to increase bonding strength after curing, which can suppress adhesive residues when being peeled from a mounting object.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a technique for producing breathable products such as filters, and more particularly to a manufacturing method and apparatus for producing breathable products having a pressure-sensitive adhesive layer on part of one surface of a breathable substrate. [Background technology]

[0002] Conventionally, breathable products such as filters for preventing dust and the like from entering a room through an air vent have been manufactured using breathable materials such as woven fabrics. In addition, such filters may have a breathable substrate made of nonwoven fabric or the like with a pressure-sensitive adhesive layer formed on one side thereof to facilitate attachment to the air vent.

[0003] Japanese Patent No. 6178291 describes a method for producing a filter having a pressure-sensitive adhesive layer made of a hot-melt pressure-sensitive adhesive on one side of a nonwoven fabric substrate. The production method described in Japanese Patent No. 6178291 includes preparing a rotationally driven relief roll having a predetermined convex pattern and a pressure roller that rotates in contact with the relief roll, adhering the hot-melt pressure-sensitive adhesive to the convex pattern, and then passing the nonwoven fabric between the relief roll and the pressure roller to transfer the hot-melt pressure-sensitive adhesive adhered to the convex pattern of the relief roll onto the nonwoven fabric, and subsequently superimposing a release paper so as to cover the hot-melt pressure-sensitive adhesive, thereby producing a filter having a hot-melt pressure-sensitive adhesive layer and release paper on one side of the substrate.

[0004] According to this manufacturing method, when the hot melt adhesive is transferred to the nonwoven fabric, it is believed that part of the hot melt adhesive penetrates into the gaps between the fibers that make up the nonwoven fabric, thereby integrating the nonwoven fabric and the adhesive layer. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent No. 6178291

[0006] The manufacturing method described in Patent Document 1 had the problem that when the hot-melt adhesive was transferred to a substrate made of nonwoven fabric, the amount of hot-melt adhesive that penetrated into the gaps in the nonwoven fabric was not constant, resulting in an inappropriate layer thickness in the portion of the adhesive layer exposed to the substrate that was uneven in some places. In the case of a filter that is attached to an object such as an air vent with an adhesive layer, if the layer thickness of the exposed portion of the adhesive layer is not appropriate, gaps are likely to form between the filter and the object, which could impair collection performance or make the filter more likely to come off the object.

[0007] Therefore, an object of the present invention is to provide a manufacturing method and manufacturing apparatus that can provide a breathable product having a pressure-sensitive adhesive layer with an appropriate layer thickness in the portion exposed to the surface of the breathable substrate. DISCLOSURE OF THE INVENTION

[0008] In order to achieve the above object, a method for producing a breathable product in a first aspect of the present invention is a method for producing a breathable product, comprising: a substrate preparation step of preparing a breathable substrate having gaps on at least one side; a hardness adjustment step of preparing a pressure-sensitive adhesive layer to be formed on part of the one side and adjusting the hardness of the pressure-sensitive adhesive layer so that only part of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate; and a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness against the breathable substrate after the hardness adjustment step, wherein the hardness adjustment step includes a hardness increase step of increasing the hardness of a region including a surface of the pressure-sensitive adhesive layer opposite to the surface that is pressed against the breathable substrate, and the pressure-sensitive adhesive layer having the adjusted hardness has an increased hardness region formed on the surface that is opposite to the surface that is pressed against the breathable substrate, and the region of the surface that is pressed against the breathable substrate is maintained in a softened state region. The adhesive layer is made of a hot melt adhesive, and the hot melt adhesive is applied in an amount of 20 to 50 g / m 2 The coating area is in the range of 40 to 80% of the entire breathable substrate. This is what is done.

[0009] With this configuration, when the pressure-sensitive adhesive layer with adjusted hardness is pressed against the breathable substrate, only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate, and the two are integrated. Also, a difference in hardness occurs in the thickness direction of the pressure-sensitive adhesive layer. Furthermore, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the gaps in the breathable substrate, while the increased hardness region does not penetrate into the gaps inside the breathable substrate. In a second aspect of the present invention, a method for producing a breathable product includes forming a pressure-sensitive adhesive layer on one side of a breathable substrate having a gap on at least one side, and disposing a release sheet on the surface side of the pressure-sensitive adhesive layer, and peeling off the release sheet to remove the breathable substrate portion using the pressure-sensitive adhesive layer. Installation a hardness adjusting step of adjusting the hardness of the adhesive layer formed on the release sheet so that only a portion of the adhesive layer penetrates into gaps in the breathable substrate; a substrate preparing step of preparing the breathable substrate; and, after the hardness adjusting step, a pressing step of pressing the adhesive layer having the adjusted hardness against the breathable substrate. The hardness adjusting step includes a hardness increasing step of increasing the hardness of a region including a surface of the adhesive layer opposite to the surface pressed against the breathable substrate, and the hardness increasing step includes a cooling step of cooling the surface of the release sheet opposite to the surface on which the adhesive layer is formed. The pressing step includes a step of pressing the adhesive layer of the release sheet having the adjusted hardness against the breathable substrate, thereby integrating the release sheet and the breathable substrate. In this configuration, by pressing the pressure-sensitive adhesive layer with adjusted hardness against the breathable substrate, only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate, and the two are integrated. Also, a difference in hardness in the thickness direction of the pressure-sensitive adhesive layer occurs. Furthermore, the release sheet and the breathable substrate are integrated in a state where the hardness of the pressure-sensitive adhesive layer is adjusted to a constant layer thickness on the release sheet in advance, and the surface of the pressure-sensitive adhesive layer is molded by the release sheet, so that it becomes flush and smooth. A method for producing a breathable product according to a third aspect of the present invention is such that, in the configuration of the invention according to the second aspect, the pressure-sensitive adhesive layer having an adjusted hardness has an increased hardness region formed on the surface opposite to the surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region. With this configuration, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the voids in the breathable substrate, whereas the increased hardness region does not penetrate into the gaps inside the breathable substrate. A method for producing a breathable product according to a fourth aspect of the present invention is the same as the method according to the first or third aspect of the present invention, in which the pressure-sensitive adhesive layer having an adjusted hardness changes continuously in the layer direction from the increased hardness region to the softened state region. With this configuration, the layer thickness of the increased hardness region is made uniform.

[0012] A fifth aspect of the present invention provides a method for producing a breathable product according to the first aspect of the invention, wherein the pressure-sensitive adhesive layer is made of a hot-melt pressure-sensitive adhesive, and the hardness increasing step is performed by increasing the hardness of the pressure-sensitive adhesive layer in a softened state. This includes the surface opposite to the surface pressed against the breathable substrate. The cooling step includes cooling the region.

[0013] In this configuration, since the adhesive is a hot melt adhesive, the hardness of the cooled area of ​​the adhesive layer increases.

[0014] The first aspect of this invention 6 In this aspect, the method for producing a breathable product is 5 In the configuration of the invention in the aspect (a), the cooling step includes a step of preparing a release sheet having a pressure-sensitive adhesive layer made of a softened hot-melt pressure-sensitive adhesive formed on one side thereof, and cooling the surface of this release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed.

[0015] In this configuration, the surface of the release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed is cooled, thereby increasing the hardness of the pressure-sensitive adhesive layer in the region close to the release sheet. The surface of the pressure-sensitive adhesive layer is formed by the release sheet, making it flush and smooth.

[0016] The first aspect of this invention 7 In this aspect, the method for producing a breathable product is 2nd stage or 6th stage In the configuration of the invention according to the aspect, the step of cooling the release sheet comprises: In release sheets This method includes a step of engaging a metal roll, the temperature of which is lower than that of the adhesive layer, with the release sheet.

[0017] With this configuration, by engaging the release sheet with a low-temperature metal roll, the temperature of the pressure-sensitive adhesive layer in the area adjacent to the release sheet decreases, and the hardness increases.

[0018] The first aspect of this invention 8 In this aspect, the method for producing a breathable product comprises the steps of: 7 In the configuration of the invention in any one of the above aspects, the breathable substrate is made of a nonwoven fabric.

[0019] When configured in this manner, by pressing the pressure-sensitive adhesive layer against the breathable substrate, part of the pressure-sensitive adhesive layer penetrates into the gaps between the fibers of the nonwoven fabric that constitutes the breathable substrate, and after curing, the breathable substrate and the pressure-sensitive adhesive layer become integrated.

[0020] The first aspect of this invention 9 In this aspect, the method for producing a breathable product comprises the steps of: 8 In one aspect of the invention, the breathable product is a filter.

[0021] By configuring in this way, a filter product can be produced that has a pressure-sensitive adhesive layer with an appropriate layer thickness in the portion exposed to the surface of the breathable substrate.

[0022] The first aspect of this invention 10 In this aspect, the method for producing a breathable product is 2 The situation , Third Phase, Fifth Phase From 7 In one aspect of the invention, the breathable product is an electrostatic filter.

[0023] By configuring in this manner, an electrostatic filter having an adhesive layer made of a hot melt adhesive is produced. In an eleventh aspect of the present invention, a method for producing a breathable product includes forming a pressure-sensitive adhesive layer on one side of a breathable substrate having a gap on at least one side, and disposing a release sheet on the surface side of the pressure-sensitive adhesive layer, and peeling off the release sheet to remove the breathable substrate portion using the pressure-sensitive adhesive layer. Installation a hardness adjusting step of adjusting the hardness of the adhesive layer formed on the release sheet so that only a portion of the adhesive layer penetrates into gaps in the breathable substrate; a substrate preparing step of preparing the breathable substrate; and, after the hardness adjusting step, a pressing step of pressing the adhesive layer having the adjusted hardness against the breathable substrate. The hardness adjusting step includes a hardness increasing step of increasing the hardness of a region of the adhesive layer including a surface opposite to the surface pressed against the breathable substrate, and the adhesive layer having the adjusted hardness has an increased hardness region formed on the surface opposite to the surface pressed against the breathable substrate, and the region of the surface pressed against the breathable substrate is maintained in a softened state. The hardness increasing step includes a cooling step of cooling the surface of the release sheet opposite to the surface on which the adhesive layer is formed. With this configuration, when the pressure-sensitive adhesive layer with adjusted hardness is pressed against the breathable substrate, only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate, and the two are integrated. Also, a difference in hardness occurs in the thickness direction of the pressure-sensitive adhesive layer. Furthermore, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the gaps in the breathable substrate, while the increased hardness region does not penetrate into the gaps inside the breathable substrate.

[0024] In a twelfth aspect of the present invention, a breathable product manufacturing apparatus includes a breathable substrate having a gap on at least one side thereof on which a pressure-sensitive adhesive layer is formed, a release sheet is disposed on the surface side of the pressure-sensitive adhesive layer, and the pressure-sensitive adhesive layer is peeled off to remove the breathable substrate portion. InstallationA manufacturing apparatus for manufacturing a breathable product to be attached to an object, the manufacturing apparatus comprising: a substrate supplying means for supplying a breathable substrate; a release sheet supplying means for supplying a release sheet; an adhesive supplying means for supplying an adhesive; an adhesive applying means for applying the adhesive supplied from the adhesive supplying means to a portion of one side of the release sheet supplied from the release sheet supplying means to form an adhesive layer; a hardness adjusting means for adjusting the hardness of the adhesive layer so that only a portion of the adhesive layer formed on the release sheet by the adhesive applying means penetrates into gaps in the breathable substrate; and a pressing means for pressing the breathable substrate supplied from the means against an adhesive layer having a hardness adjusted by the hardness adjusting means, the hardness adjusting means including a hardness increasing means for increasing the hardness of a region including the surface of the adhesive layer opposite to the surface pressed against the breathable substrate, the adhesive layer having the adjusted hardness has an increased hardness region formed on the surface opposite to the surface pressed against the breathable substrate, and the region of the surface pressed against the breathable substrate is maintained in a softened state, and the hardness increasing means includes a cooling means for cooling the side of the release sheet opposite to the surface on which the adhesive layer is formed.

[0025] When configured in this manner, the hardness of the adhesive layer applied to the release sheet by the adhesive application means is adjusted by the hardness adjustment means, and then the breathable substrate is pressed against the adhesive layer by the pressing means, thereby laminating the adhesive layer and the release sheet on one side of the breathable substrate and allowing part of the adhesive layer to penetrate into the gaps in the breathable substrate, resulting in a manufacturing device that can produce a breathable product with an integrated structure. In a thirteenth aspect of the present invention, a breathable product manufacturing apparatus is provided, which includes: a breathable substrate having a gap on at least one side; a pressure-sensitive adhesive layer is formed on one side of the breathable substrate; a release sheet is disposed on the surface side of the pressure-sensitive adhesive layer; and the release sheet is peeled off and the breathable substrate portion is removed using the pressure-sensitive adhesive layer. Installationa hardness adjusting means for adjusting the hardness of the adhesive layer so that only a portion of the adhesive layer formed on the release sheet by the adhesive applying means penetrates into gaps in the breathable substrate; and a pressing means for pressing the breathable substrate supplied from the substrate supplying means against the adhesive layer having a hardness adjusted by the hardness adjusting means, and for integrating the release sheet and the breathable substrate. The hardness adjusting means includes a hardness increasing means for increasing the hardness of a region of the adhesive layer including a surface opposite to the surface pressed against the breathable substrate, and the hardness increasing means includes a cooling means for cooling the surface of the release sheet opposite to the surface on which the adhesive layer is formed. When configured in this manner, the hardness of the adhesive layer applied to the release sheet by the adhesive application means is adjusted by the hardness adjustment means, and then the breathable substrate is pressed against the adhesive layer by the pressing means, thereby laminating the adhesive layer and the release sheet on one side of the breathable substrate and allowing part of the adhesive layer to penetrate into the gaps in the breathable substrate, resulting in a manufacturing device that can produce a breathable product with an integrated structure.

[0026] The first aspect of this invention 4 The manufacturing device for the breathable product in this aspect is 2 In the configuration of the invention in this aspect, the pressure-sensitive adhesive is a hot-melt pressure-sensitive adhesive, and the hardness adjusting means includes a metal roll that engages with the release sheet on which the pressure-sensitive adhesive layer is formed and cools the release sheet.

[0027] When configured in this manner, the manufacturing apparatus includes a metal roll for cooling the release sheet on which the pressure-sensitive adhesive layer is formed. The first aspect of this invention 5 The manufacturing device for the breathable product in this aspect is 3In the configuration of the invention in the above aspect, the cooling means includes a metal roll that engages with the release sheet on which the pressure-sensitive adhesive layer is formed. When configured in this manner, the manufacturing apparatus includes a metal roll for cooling the release sheet on which the pressure-sensitive adhesive layer is formed.

[0028] As described above, the method for producing a breathable product according to the first aspect of the present invention presses a pressure-sensitive adhesive layer with an adjusted hardness against a breathable substrate, thereby adjusting the extent to which the pressure-sensitive adhesive layer penetrates into the breathable substrate. This allows a breathable product to be obtained in which the thickness of the portion of the pressure-sensitive adhesive layer exposed on the surface is optimized. Furthermore, by allowing a portion of the pressure-sensitive adhesive layer to penetrate into the gaps in the breathable substrate, the two are integrated after curing, increasing the bonding strength, thereby reducing adhesive residue when the product is peeled off from the object to which it is attached. Furthermore, by adjusting the difference in hardness in the thickness direction of the pressure-sensitive adhesive layer, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the voids in the breathable substrate, while the region of increased hardness does not penetrate into the gaps inside the breathable substrate, making it possible to control the ratio of the part of the pressure-sensitive adhesive layer that penetrates into the breathable substrate and the part that is exposed on the surface of the breathable substrate. In a second aspect of the present invention, a method for producing a breathable product involves pressing a pressure-sensitive adhesive layer with an adjusted hardness against a breathable substrate, thereby adjusting the extent to which the pressure-sensitive adhesive layer penetrates into the breathable substrate. This allows for the production of a breathable product in which the layer thickness of the portion of the pressure-sensitive adhesive layer exposed on the surface is optimized. Furthermore, by allowing a portion of the pressure-sensitive adhesive layer to penetrate into the gaps in the breathable substrate, the two are integrated after curing, increasing the bonding strength, thereby reducing adhesive residue when the breathable product is peeled from the object to which it is attached. Furthermore, the release sheet and the breathable substrate are integrated in a state in which the hardness of the pressure-sensitive adhesive layer is adjusted to a constant layer thickness on the release sheet, and the surface of the pressure-sensitive adhesive layer is molded by the release sheet, resulting in a flush and smooth surface. This reduces the likelihood of gaps forming between the breathable product and the object when the breathable product is attached to the object. In addition to the effects of the second aspect of the invention, the method for producing a breathable product according to the third aspect of the present invention adjusts the difference in hardness in the thickness direction of the pressure-sensitive adhesive layer so that when the pressure-sensitive adhesive layer is pressed against a breathable substrate, the softened region penetrates into the voids in the breathable substrate, while the increased hardness region does not penetrate into the gaps inside the breathable substrate, making it possible to control the ratio of the part of the pressure-sensitive adhesive layer that penetrates into the breathable substrate to the part that is exposed on the surface of the breathable substrate. In addition to the effects of the invention in the first or third aspects, the method for manufacturing a breathable product in the fourth aspect of the present invention makes the layer thickness of the increased hardness region uniform, making it less likely that a gap will occur between the breathable product and the object when the breathable product is attached to the object.

[0030] The first aspect of this invention 5 In this aspect, the method for producing a breathable product is 1 In addition to the effects of the invention in this aspect, the range in which the hardness of the pressure-sensitive adhesive layer is increased can be adjusted by controlling the cooling temperature, cooling time, etc. Therefore, the thickness of the exposed portion of the pressure-sensitive adhesive layer can be easily adjusted to an appropriate value by a simple process.

[0031] The first aspect of this invention 6 In this aspect, the method for producing a breathable product is 5 In addition to the effects of the invention in aspect 1, the cooling step can be carried out with a cooling means having a simple configuration, since the pressure-sensitive adhesive layer is cooled via the release sheet. The release sheet makes the surface of the pressure-sensitive adhesive layer flush and smooth, resulting in a breathable product that can be easily attached to an object.

[0032] The first aspect of this invention 7 In this aspect, the method for producing a breathable product is 2nd stage or 6th stageIn addition to the effects of the invention in the above aspect, the metal roll can have a large heat capacity and high thermal conductivity, so by contacting the metal roll with the release sheet, the hardness of a part of the pressure-sensitive adhesive layer can be increased in a short time, thereby accelerating the curing process of the pressure-sensitive adhesive layer and improving the production efficiency of breathable products.

[0033] The first aspect of this invention 8 In this aspect, the method for producing a breathable product comprises the steps of: 7 In addition to the effects of the invention in any one of the above aspects, since the hardness of the pressure-sensitive adhesive layer is adjusted beforehand and then the pressure-sensitive adhesive layer is pressed against the breathable substrate, the thickness of the exposed portion of the pressure-sensitive adhesive layer can be made approximately uniform even in the case of a nonwoven fabric in which the layer thickness is likely to be uneven.

[0034] The first aspect of this invention 9 In this aspect, the method for producing a breathable product comprises the steps of: 8 In addition to the effects of the invention in any one of the above aspects, since the thickness of the exposed portion of the adhesive layer is appropriate, it is possible to produce a filter product that can be attached without gaps to an object to which it is to be attached, such as an air vent.

[0035] The method for producing a breathable product according to a tenth aspect of the present invention achieves the effects of the invention according to any one of the second, third, and fifth to seventh aspects, and in addition, the pressure-sensitive adhesive layer of the electrostatic filter is formed from a hot-melt pressure-sensitive adhesive, thereby suppressing the deterioration of electrostatic function that occurs when the pressure-sensitive adhesive layer is formed from a conventional solvent-based pressure-sensitive adhesive, and making it possible to produce an electrostatic filter product that has excellent efficiency in collecting ultrafine particles such as PM2.5. In an eleventh aspect of the present invention, a method for producing a breathable product involves pressing a pressure-sensitive adhesive layer with an adjusted hardness against a breathable substrate, thereby adjusting the extent to which the pressure-sensitive adhesive layer penetrates into the breathable substrate. This allows for the production of a breathable product in which the thickness of the portion of the pressure-sensitive adhesive layer exposed on the surface is optimized. Furthermore, by allowing a portion of the pressure-sensitive adhesive layer to penetrate into the gaps in the breathable substrate, the two become integrated after curing, increasing the bonding strength, thereby reducing adhesive residue when the product is peeled from the attachment target. Furthermore, by adjusting the difference in hardness across the thickness of the pressure-sensitive adhesive layer, when the pressure-sensitive adhesive layer is pressed against the breathable substrate, the softened region penetrates into the voids in the breathable substrate, while the increased hardness region does not penetrate into the gaps within the breathable substrate. This allows for the ratio of the pressure-sensitive adhesive layer penetrating the breathable substrate to the portion exposed on the surface of the breathable substrate to be controlled.

[0036] The first aspect of this invention 2 The breathable product manufacturing apparatus in this aspect can provide a breathable product in which the thickness of the pressure-sensitive adhesive layer exposed on the surface of the breathable substrate is appropriate, and the surface of the pressure-sensitive adhesive layer is molded flush and smooth by the release sheet. The first aspect of this invention 3The breathable product manufacturing apparatus in this aspect can provide a breathable product in which the thickness of the pressure-sensitive adhesive layer exposed on the surface of the breathable substrate is appropriate, and the surface of the pressure-sensitive adhesive layer is molded flush and smooth by the release sheet.

[0037] The first aspect of this invention 4 The manufacturing device for the breathable product in this aspect is 2 In addition to the effects of the above aspect, by appropriately selecting the material and size of the metal roll, it is possible to provide high thermal conductivity and large heat capacity, and therefore by cooling the release sheet, it is possible to increase the hardness of the pressure-sensitive adhesive layer in the vicinity of the release sheet in a short period of time. Furthermore, by appropriately selecting the size and rotation speed of the metal roll, it is possible to control the contact area and contact time with the release sheet, and easily adjust the range in which the hardness of the pressure-sensitive adhesive layer is increased. Therefore, by including such a metal roll, it is possible to realize a hardness adjustment means with a simple configuration that has high control accuracy and reliability. Furthermore, the metal roll makes it possible to speed up the hardness adjustment process of the pressure-sensitive adhesive layer, and therefore it is possible to provide a manufacturing device that can efficiently produce breathable products in which the exposed portions of the pressure-sensitive adhesive layer have a uniform layer thickness. The first aspect of this invention 5 The manufacturing device for the breathable product in this aspect is 3 In addition to the effects of the above aspect, by appropriately selecting the material and size of the metal roll, it is possible to provide high thermal conductivity and large heat capacity, and therefore by cooling the release sheet, it is possible to increase the hardness of the pressure-sensitive adhesive layer in the vicinity of the release sheet in a short period of time. Furthermore, by appropriately selecting the size and rotation speed of the metal roll, it is possible to control the contact area and contact time with the release sheet, and easily adjust the range in which the hardness of the pressure-sensitive adhesive layer is increased. Therefore, by including such a metal roll, it is possible to realize a hardness adjustment means with a simple configuration that has high control accuracy and reliability. Furthermore, the metal roll makes it possible to speed up the hardness adjustment process of the pressure-sensitive adhesive layer, and therefore it is possible to provide a manufacturing device that can efficiently produce breathable products in which the exposed portions of the pressure-sensitive adhesive layer have a uniform layer thickness. [Brief explanation of the drawings]

[0038] [Figure 1] 1A and 1B are diagrams showing an example of a breathable product according to an embodiment of the present invention, in which (A) is a partially omitted plan view, and (B) is an enlarged cross-sectional view of a portion of (A). [Figure 2] 1 is a schematic diagram showing an example of a manufacturing apparatus for manufacturing a breathable product according to an embodiment of the present invention. [Figure 3] FIG. 3 is an enlarged view of part A in FIG. 2. [Figure 4] FIG. 4 is an enlarged cross-sectional view taken along line IV-IV in FIG. 3. [Figure 5] FIG. 3 is an enlarged view of part B in FIG. 2. [Figure 6] FIG. 6 is an enlarged cross-sectional view taken along line VI-VI in FIG. 5. [Figure 7] FIG. 3 is an enlarged view of part C in FIG. 2. [Figure 8] FIG. 8 is an enlarged cross-sectional view taken along line VIII-VIII in FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0039] [Breathable products] FIG. 1 shows an example of a breathable product according to an embodiment of the present invention, where (A) is a partially omitted plan view and (B) is an enlarged cross-sectional view of a portion of (A).

[0040] Referring to the figure, the breathable product F produced by the present invention is, for example, a filter that is attached to an object to filter gas passing through, and includes a breathable substrate S1 having gaps on at least one side thereof, and a pressure-sensitive adhesive layer N formed on part of one side of the breathable substrate S1. In this example, the breathable substrate S1 also includes a release sheet S2 disposed on the surface side of the pressure-sensitive adhesive layer N. Part of the pressure-sensitive adhesive layer N penetrates into the gaps in the breathable substrate S1.

[0041] The breathable substrate S1 may be made of a nonwoven fabric, a woven fabric, a knitted fabric, or a combination thereof. Polypropylene or a propylene-based copolymer is often used as the material for the breathable substrate S1. To impart flame retardancy, the above synthetic resin raw material may be mixed with an appropriate amount of a fatty acid metal salt such as aluminum stearate or flame-retardant fibers.

[0042] When the breathable product F is a filter, the breathable substrate S1 has a thickness of 0.3 to 15.0 mm and a basis weight of 20 to 200 g / m 2 With this configuration, it is possible to reliably capture dust particles in the air while allowing gas to pass through, and it also has practical strength. 2 If the thickness is less than 15.0 mm, the strength may be insufficient for practical use and the collection function may not be sufficient. 2 If the thickness exceeds this value, the gas flow resistance will increase, and the practicality of the air filter may be impaired.

[0043] The adhesive layer N preferably uses a solvent-free adhesive such as a hot-melt adhesive or an emulsion-type adhesive.

[0044] As the hot melt adhesive, any conventionally known hot melt adhesive can be used, and specific examples include ethylene vinyl acetate, polyolefin, polyamide, synthetic rubber, acrylic, polyurethane, etc. For filters, among the above, it is preferable to use a synthetic rubber hot melt adhesive, taking into consideration the holding power when attached to an object such as an air vent, the tendency to leave no adhesive residue, etc.

[0045] When a synthetic rubber-based hot-melt pressure-sensitive adhesive is used as the hot-melt pressure-sensitive adhesive, examples of the synthetic rubber component contained therein include styrene-based elastomers such as styrene-butadiene block copolymer, styrene-isoprene block copolymer, and hydrogenated products of these block copolymers, polyisobutylene, butyl rubber (isobutylene-isoprene copolymer and modified products of said polymer), olefin-based elastomers such as polybutene, polychloroprene, nitrile rubber, etc. These synthetic rubber components function as elastomers, thereby improving the cohesive strength of the pressure-sensitive adhesive and thereby improving its adhesive strength.

[0046] The hot melt adhesive may also contain one or more of the ingredients listed below. Tackifying resins such as rosin resins, terpene resins, (hydrogenated) petroleum resins, coumarone-indene resins, hydrogenated aromatic copolymers, styrene resins, phenolic resins, xylene resins, etc.; · Plasticizers such as phthalates, adipates, sebacates, other fatty acid esters, paraffins, epoxy polymer plasticizers, phosphates, phosphites, acrylic oligomers, polyisoprene, process oils, naphthenic oils, polyester polyols, polyether polyols, and polyol compounds; Other polymers such as ethylene-ethyl acrylate copolymer, ethylene-vinyl acetate copolymer, polyvinyl acetate, etc. The above components may be used alone or in combination of two or more, and act as tackifiers for the adhesive, improving the adhesiveness (adhesion) of the adhesive to the breathable substrate.

[0047] In addition to the above components, other components that can be contained in the hot melt adhesive can be one or a combination of two or more of the following: mineral oils (synthetic oils) such as petroleum hydrocarbons, vegetable oils, animal oils, paraffins, terpenoids, fatty acids, fatty acid esters, alcohols, honey, crotamiton, etc. All of these components act as softeners for the adhesive and have the function of preventing the adhesive strength of the adhesive from decreasing at low temperatures.

[0048] The above-mentioned components also function to improve the coatability of the adhesive. For example, depending on the type, molecular weight, content, etc. of the elastomer component constituting the synthetic rubber-based hot-melt adhesive, stringiness or the like may occur during application of the adhesive. In such cases, adding a softener to the adhesive can effectively prevent stringiness or the like, thereby achieving good coatability. Furthermore, by including the above-mentioned components in the adhesive, it is possible to suppress the hot-melt adhesive from leaving residue, i.e., adhesive residue, on the target object when the electrostatic filter structure of the present invention is peeled off from the target object, such as an air vent, after use.

[0049] The release sheet S2 is made of a thin sheet-like material that can hold the applied adhesive on its surface without absorbing it and has good release properties for the adhesive. Examples of such materials include polyester films such as polyethylene terephthalate (PET) film and polyolefin films such as polypropylene (PP) film, and the surface of these films may be coated with a release agent such as silicone resin to improve release properties. [Manufacturing equipment] Next, a manufacturing apparatus for manufacturing the breathable product according to the present invention will be described.

[0050] FIG. 2 is a schematic diagram showing an example of a manufacturing apparatus for manufacturing a breathable product according to an embodiment of the present invention.

[0051] Referring to the figure, the manufacturing apparatus P of the present invention includes a substrate supplying means for supplying a breathable substrate S1, a release sheet supplying means for supplying a release sheet S2, an adhesive supplying means for supplying an adhesive M, an adhesive applying means for applying the adhesive M supplied from the adhesive supplying means to a part of one side of the release sheet S2 supplied from the release sheet supplying means to form an adhesive layer, a hardness adjusting means for adjusting the hardness of the adhesive layer so that only a part of the adhesive layer penetrates into the gaps in the breathable substrate S1, and a pressing means for pressing the breathable substrate S1 supplied from the substrate supplying means against the adhesive layer having the adjusted hardness.

[0052] In this example, for example, the breathable substrate S1 is a nonwoven fabric, the release sheet S2 is a PET film, and the adhesive M is a hot-melt adhesive that is in a hardened state at room temperature and softens when heated.

[0053] In the manufacturing apparatus P of this example, the breathable substrate S1 supply means includes supply rolls 10 and 11 for adjusting the transport speed of the breathable substrate S1 while supplying it, and transport rolls 12, 13, and 14 for transporting the breathable substrate S1. The adhesive M supply means includes an adhesive supply roll 2 and an auxiliary roll 1 for storing and dispensing the adhesive M. The adhesive application means includes an application roll 3 and a backup roll 4 for applying the adhesive M supplied from the adhesive supply roll 2 to form an adhesive layer N of a predetermined pattern. The hardness adjustment means includes a metal roll 7 that contacts the surface of the release sheet S2 opposite to the surface on which the adhesive layer N is formed. The pressing means includes nip rolls 5 and 6 for laminating and pressing the breathable substrate S1 supplied from the breathable substrate supply means and the release sheet S2, the hardness of which has been adjusted, to bond them together. Note that a known mechanism can be used for the release sheet S2 supply means, and illustrations thereof are omitted.

[0054] The auxiliary roll 1, adhesive supply roll 2, application roll 3, and backup roll 4 are arranged adjacent to each other and are configured to rotate in unison. Molten adhesive M is stored above the area where the adhesive supply roll 2 and auxiliary roll 1 butt together. When the adhesive supply roll 2 is rotated, the adhesive M adhering to its surface is transferred to the surface of the application roll 3 that is in contact with it. The amount of transferred adhesive M can be controlled by adjusting the size of the gap between the adhesive supply roll 2 and auxiliary roll 1.

[0055] A known printing roll such as a gravure roll or letterpress roll can be used as the applicator roll 3. Furthermore, by forming the surface of the applicator roll 3 into a metal surface, the releasability is improved, and the transfer of the pressure-sensitive adhesive M from the applicator roll 3 to the release sheet S2 is made smooth.

[0056] When a release sheet S2 is passed between an applicator roll 3, on the surface of which adhesive M transferred from an adhesive supply roll 2 is adhered, and a backup roll 4, the adhesive M is applied to one side of the release sheet S2, thereby forming an adhesive layer N. The adhesive layer N can also be in the form of letters, designs, etc.

[0057] The metal roll 7, which is brought into contact with the surface of the release sheet S2 opposite to the surface on which the pressure-sensitive adhesive layer N is formed, is made of a metal with high thermal conductivity such as copper, brass, aluminum, iron, or stainless steel. The heat capacity can be set by appropriately selecting the material and outer dimensions. The contact area between the metal roll 7 and the release sheet S2 can be set by the diameter of the metal roll 7, the position of the metal roll 7 relative to the path of the release sheet S2, etc. The metal roll 7 may be equipped with an appropriate heat dissipation mechanism or cooling mechanism. The metal roll 7 can also have a tensor function that applies tension to the release sheet. [Manufacturing method] Next, a method for producing a breathable product according to the present invention using the above-mentioned production apparatus P will be described.

[0058] Fig. 3 is an enlarged view of part A in Fig. 2. Fig. 4 is an enlarged cross-sectional view taken along line IV-IV in Fig. 3. Fig. 5 is an enlarged view of part B in Fig. 2. Fig. 6 is an enlarged cross-sectional view taken along line VI-VI in Fig. 5. Fig. 7 is an enlarged view of part C in Fig. 2. Fig. 8 is an enlarged cross-sectional view taken along line VIII-VIII in Fig. 7.

[0059] With reference to these figures, the manufacturing method of the present invention comprises a substrate preparation step of preparing a breathable substrate S1 having gaps on at least one side, a hardness adjustment step of preparing an adhesive layer to be formed on part of one side and adjusting the hardness of the adhesive layer so that only part of the adhesive layer penetrates into the gaps in the breathable substrate S1, and a pressing step of pressing the adhesive layer with the adjusted hardness against the breathable substrate S1.

[0060] In this example, the substrate preparing step is carried out by a means for supplying the breathable substrate S1. The pressure-sensitive adhesive layer preparing step is carried out by applying the pressure-sensitive adhesive M to one side of the release sheet S2 with the application roll 3. The hardness adjusting step is carried out by bringing a metal roll 7 into contact with the opposite side of the release sheet S2 on which the pressure-sensitive adhesive layer has been formed. The pressing step is carried out by passing the surface of the release sheet S2 on which the pressure-sensitive adhesive layer has been formed and the breathable substrate S1 between nip rolls 5 and 6 while they are facing each other.

[0061] The method for producing the breathable product F in this example will be described in detail below.

[0062] Referring to Figure 2, in the manufacturing device P, by rotating the adhesive supply roll 2, the molten adhesive M stored at the top of the joint between the adhesive supply roll 2 and the auxiliary roll 1 is transferred to the surface of the application roll 3 that is in contact with the adhesive supply roll 2.

[0063] Then, as shown in FIG. 3, the release sheet S2 supplied from the supply means is passed between the application roll 3 and the backup roll 4, whereby the adhesive M is applied in a predetermined pattern to one side of the release sheet S2, and as shown in FIG. 4, an adhesive layer N in a predetermined pattern is formed on the release sheet S2.

[0064] Next, the release sheet S2 on which the pressure-sensitive adhesive layer N has been formed is transported to the position of the metal roll 7, and as shown in FIG. 5, the surface on which the pressure-sensitive adhesive layer N has not been formed is engaged with the metal roll 7. The metal roll 7 is configured to be cooler than the temperature of the pressure-sensitive adhesive layer N, have excellent thermal conductivity, and have sufficient heat capacity. Therefore, as shown in FIG. 6, the pressure-sensitive adhesive layer N in a softened state on the release sheet S2 is cooled by the metal roll 7 through the release sheet S2, and the region of the pressure-sensitive adhesive layer N near the release sheet S2 becomes an increased hardness region N1 in which the hardness has increased due to the temperature drop. In contrast, the surface side region of the pressure-sensitive adhesive layer N away from the release sheet S2 is maintained in a softened state region N2 that has fluidity.

[0065] Since the contact between the release sheet S2 and the metal roll 7 is almost uniform at every part, it is thought that the temperature drop of the adhesive layer N caused by this contact is carried out almost uniformly. Therefore, the layer thickness of the increased hardness region N1 in the adhesive layer N is made almost uniform.

[0066] In Figure 6, for the sake of convenience, the boundary between the two regions, the increased hardness region N1 and the softened state region N2, is represented by a dashed line, but in reality, the hardness changes continuously from the region of the adhesive layer N near the release sheet S2 to the surface region of the adhesive layer N away from the release sheet S2.

[0067] Furthermore, the degree and range of hardness increase of the adhesive layer N can be controlled by adjusting the temperature, thermal conductivity, heat capacity, contact area and contact time with the release sheet S2 of the metal roll 7, and therefore the layer thickness of the hardness increase region N1 can be easily adjusted.

[0068] In this way, the release sheet S2, for which the hardness adjusting step of the pressure-sensitive adhesive layer N has been performed, is transported to the position of the nip rolls 5 and 6. On the other hand, the breathable substrate S1 is also transported to the position of the nip rolls 5 and 6 by supply rolls 10 and 11 and transport rolls 12, 13 and 14. At this time, the transport speeds of the breathable substrate S1 and the release sheet S2 are controlled so that they coincide at the positions of the nip rolls 5 and 6.

[0069] The breathable substrate S1 and release sheet S2 are supplied to nip rolls 5 and 6, and as shown in Fig. 7, the breathable substrate S1 is faced to the surface of the release sheet S2 on which the pressure-sensitive adhesive layer N has been formed, and the two are passed between the nip rolls 5 and 6. As a result, the pressure-sensitive adhesive layer N on the release sheet S2 is pressed against the breathable substrate S1, and a breathable product F is produced in which the two are integrated.

[0070] When the pressure-sensitive adhesive layer N is pressed against the breathable substrate S1, the softened region N2 located on the surface side of the pressure-sensitive adhesive layer N penetrates into the voids in the breathable substrate S1 due to its fluidity, as shown in Figure 8. On the other hand, the increased hardness region N1 in the pressure-sensitive adhesive layer N near the release sheet S2 does not penetrate into the voids inside the breathable substrate S1 due to its low fluidity, and remains on the surface of the breathable substrate S1.

[0071] The portion of the pressure-sensitive adhesive layer N that penetrates into the breathable substrate S1 forms an anchor layer R after curing, and exhibits excellent bonding strength to the pressure-sensitive adhesive layer N. Therefore, when the release sheet S2 is peeled off during use of the product, there is no risk of adhesive residue remaining on the surface of the pressure-sensitive adhesive layer N.

[0072] On the other hand, the increased hardness region N1 of the pressure-sensitive adhesive layer N forms an exposed layer Q exposed on the surface of the breathable substrate S1 after curing. By adjusting the layer thickness of the increased hardness region N1 to a substantially constant value, the layer thickness of the exposed layer Q can also be formed appropriately and substantially uniformly. This reduces the likelihood of gaps forming between the breathable product F and the object when it is attached to the object. Furthermore, if the softened region N2, which is the portion of the pressure-sensitive adhesive layer N that penetrates into the breathable substrate S1, has a significantly low viscosity or if the voids in the breathable substrate S1 are large, the softened region N2 may penetrate into the voids in the breathable substrate S1 more than expected before curing, resulting in the pressure-sensitive adhesive layer N penetrating the surface of the breathable substrate S1 opposite the surface on which the exposed layer Q is formed. If such penetration occurs, when the breathable substrate S1 and the release sheet S2 are laminated and pressed together and passed between nip rolls 5 and 6, problems such as the pressure-sensitive adhesive layer N that has penetrated the breathable substrate S1 sticking to the nip rolls 6 and the laminate of the breathable substrate S1 and the release sheet S2 wrapping around the nip rolls 6, or the breathable substrate S1 alone sticking to and being pulled by the nip rolls 6 and separating the laminate of the breathable substrate S1 and the release sheet S2, or a part of the breathable substrate S1 being pulled toward the nip rolls 6 and causing tearing of the breathable substrate S1 (hereinafter referred to as a first problem) may occur. Furthermore, even if the breathable substrate S1 passes between the nip rolls 5 and 6, if a transport roll (not shown) is used for transport to the next process, a problem (hereinafter referred to as a second problem) may occur due to the breathable substrate S1 sticking to the transport roll, similar to the adhesive layer N sticking to the nip roll 6 mentioned above. In order to prevent such first and second defects, the softened region N2 may be cooled and hardened before the pressure-sensitive adhesive layer N penetrates to the side opposite to the side on which the exposed layer Q of the breathable substrate S1 is formed. To achieve this, for example, to address the first defect, a cooling mechanism may be provided on the nip roll 6 itself on the side that contacts the breathable substrate S1, and to address the second defect, a cooling mechanism may be provided between the nip roll 6 and the conveying roll of the next process to cool the side of the breathable substrate S1 opposite to the side on which the exposed layer Q is formed.However, even when such a cooling mechanism is provided, it is preferable to balance the degree of cooling so as not to inhibit penetration of the adhesive layer N into the breathable substrate S1, thereby preventing the formation of the anchor layer R described above.

[0073] The breathable product F manufactured as described above is cut to a predetermined size as needed and commercialized, and sold as a filter product with a release sheet. When using it, the release sheet S2 is peeled off at the work site, and the breathable substrate S1 portion made of nonwoven fabric or the like is attached to the target object using the adhesive layer N.

[0074] In this example, the adhesive layer N is not formed on the entire surface of the breathable substrate S1, but is formed partially by pattern coating. When the adhesive M is a hot melt adhesive, the preferred amount of application is 20 to 50 g / m 2 , more preferably 25 to 35 g / m 2 The preferred application area of ​​the hot melt adhesive is usually in the range of 40 to 80% of the entire breathable substrate S1. However, the above values ​​can be changed as appropriate depending on the application and size of the breathable product F. [Other embodiments] The embodiments of the present invention are not limited to those described above.

[0075] The breathable substrate may be a nonwoven fabric, a woven fabric, a knitted fabric, or a combination thereof.

[0076] As the adhesive, in addition to a hot melt adhesive, an emulsion adhesive, an ultraviolet curing adhesive, etc. can be used.

[0077] In addition to using a metal roll, the hardness of the adhesive layer can be adjusted by contacting a belt that moves at the same speed as the release sheet's conveyance speed with the release sheet on the side opposite to the side on which the adhesive layer is formed. Alternatively, this can be done by spraying cooling gas onto the opposite side. When an ultraviolet-curing adhesive is used for the adhesive layer, the hardness of the adhesive layer can be adjusted by irradiating ultraviolet light from the side of the release sheet opposite to the side on which the adhesive layer is formed.

[0078] The adhesive supplying means may be a tank that stores the adhesive in a fluid state, and the adhesive may be supplied directly from the tank to the adhesive supply roll.

[0079] The adhesive application means may be a roll coating method using an application roll, or may be a spray coating method, an ink jet method, a die coating method, a screen printing method, or the like.

[0080] The breathable products produced by the present invention can be widely used as components for air filter products in indoor and outdoor vents, ventilation points in industrial equipment, and breathable hygiene products such as masks, diapers, sheets, and clothing, as well as for household appliances such as kitchen and kitchen range hoods, air conditioners, air purifiers, and ventilation fans, to which they are attached.

[0081] The present invention can be applied to the manufacture of electrostatic filters. Electrostatic filters use electrostatic force to efficiently capture and remove fine particles in air, and have been increasingly used in recent years due to their ability to effectively remove ultrafine particles known as PM2.5, which have a particle diameter of 2.5 μm or less and are feared to have a serious impact on the human respiratory system.

[0082] When producing an electrostatic filter according to the present invention, an electrostatically active nonwoven fabric is used as the breathable substrate. Examples of such nonwoven fabrics include a combination of polyester fiber (PET fiber) and modacrylic fiber that has been subjected to an electrification process, a polypropylene nonwoven fabric that has been subjected to an electrification process by corona discharge treatment, a nonwoven fabric containing wool fiber that has been subjected to a resin treatment and then subjected to an electrification process by a tanning process, and a core-sheath composite fiber in which the surface of polypropylene resin is coated with polyethylene resin and the fiber surface is polarized and charged by generating a high DC electric field using an applied electrode.

[0083] Furthermore, when manufacturing an electrostatic filter based on the present invention, the use of a hot melt adhesive as the adhesive improves the collection effect for ultrafine particles such as PM2.5 compared to when conventional solvent-based adhesives are used.

[0084] The details of the mechanism by which the use of hot-melt adhesives improves the PM2.5 collection efficiency compared to conventional solvent-based adhesives are unknown. One hypothesis is that conventional adhesives are diluted with a solvent such as ethyl acetate before use, and when this is applied to an electrostatic filter, static electricity is generated at the interface between the adhesive and the electrostatic filter or within the adhesive due to the flow during application, which cancels out the charge on the electrostatic filter, thereby reducing the PM2.5 collection efficiency of the electrostatic filter structure.

[0085] Therefore, based on the above speculation, it is thought that the reason why the use of hot melt adhesives improves the PM2.5 collection efficiency is because the hot melt adhesive flows less when pressed against a breathable substrate, and because it does not contain solvents, static electricity is less likely to occur at the interface with the breathable substrate or inside the adhesive layer.

[0086] In addition, the present invention can be applied in various ways and modified appropriately according to the implementation situation. [Industrial Applicability]

[0087] The present invention can produce breathable products in which the thickness of the adhesive layer formed on the breathable substrate such as a nonwoven fabric is made uniform, and therefore can provide air filter products that attach well to objects such as range hoods, air conditioners, air purifiers, ventilation fans, and vents, and that leave little adhesive residue, as well as constituent materials for breathable sanitary products.

Claims

1. A method for producing a breathable product (F), comprising: A substrate preparation step of preparing an air-permeable substrate (S1) having a gap on at least one side; a hardness adjusting step of preparing a pressure-sensitive adhesive layer (N) to be formed on a portion of the one surface side and adjusting the hardness of the pressure-sensitive adhesive layer so that only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate; a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness onto the breathable substrate after the hardness adjusting step, the hardness adjusting step includes a hardness increasing step of increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate, the pressure-sensitive adhesive layer having the adjusted hardness has an increased hardness region formed on a surface opposite to a surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region; The pressure-sensitive adhesive layer is made of a hot-melt pressure-sensitive adhesive (M), The hot melt adhesive has a coating amount of 20 to 50 g / m ２ and the application area is in the range of 40 to 80% of the entire breathable substrate.

2. A method for producing a breathable product (F) in which a pressure-sensitive adhesive layer (N) is formed on one side of a breathable substrate (S1) having a gap on at least one side, and a release sheet (S2) is arranged on the surface side of the pressure-sensitive adhesive layer, and the release sheet is peeled off, and the breathable substrate portion is attached to an object to be attached using the pressure-sensitive adhesive layer, preparing a pressure-sensitive adhesive layer to be formed on a portion of the one surface side, and forming the pressure-sensitive adhesive layer on the release sheet; a hardness adjusting step of adjusting the hardness of the pressure-sensitive adhesive layer formed on the release sheet so that only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate; a substrate preparation step of preparing the breathable substrate; a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness onto the breathable substrate after the hardness adjusting step, the hardness adjusting step includes a hardness increasing step of increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate, the hardness increasing step includes a cooling step of cooling the surface of the release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed, The method for producing a breathable product includes a step of pressing the pressure-sensitive adhesive layer having the adjusted hardness of the release sheet onto the breathable substrate to integrate the release sheet and the breathable substrate.

3. 3. The method for producing a breathable product according to claim 2, wherein the pressure-sensitive adhesive layer having the adjusted hardness has an increased hardness region formed on a surface opposite to the surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region.

4. The method for producing a breathable product according to claim 1 or 3, wherein the pressure-sensitive adhesive layer having the adjusted hardness has a hardness that changes continuously in the layer direction from the increased hardness region to the softened state region.

5. The pressure-sensitive adhesive layer is made of a hot-melt pressure-sensitive adhesive (M), The method for producing a breathable product according to claim 1 , wherein the hardness increasing step includes a cooling step of cooling a region of the softened pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate.

6. 6. The method for producing a breathable product according to claim 5, wherein the cooling step includes a step of preparing a release sheet (S2) having a pressure-sensitive adhesive layer made of a softened hot-melt pressure-sensitive adhesive formed on one side thereof, and cooling the surface of the release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed.

7. 7. The method for producing a breathable product according to claim 2 or 6, wherein the step of cooling the release sheet includes a step of engaging the release sheet with a metal roll (7) having a temperature lower than that of the pressure-sensitive adhesive layer of the release sheet.

8. The method for producing a breathable product according to any one of claims 1 to 7, wherein the breathable substrate is made of a nonwoven fabric.

9. The method for producing a breathable product according to any one of claims 1 to 8, wherein the breathable product is a filter.

10. The method for producing a breathable product according to any one of claims 2, 3, and 5 to 7, wherein the breathable product is an electrostatic filter.

11. A method for producing a breathable product (F) in which a pressure-sensitive adhesive layer (N) is formed on one side of a breathable substrate (S1) having a gap on at least one side, and a release sheet (S2) is arranged on the surface side of the pressure-sensitive adhesive layer, and the release sheet is peeled off, and the breathable substrate portion is attached to an object to be attached using the pressure-sensitive adhesive layer, preparing a pressure-sensitive adhesive layer to be formed on a portion of the one surface side, and forming the pressure-sensitive adhesive layer on the release sheet; a hardness adjusting step of adjusting the hardness of the pressure-sensitive adhesive layer formed on the release sheet so that only a portion of the pressure-sensitive adhesive layer penetrates into the gaps in the breathable substrate; a substrate preparation step of preparing the breathable substrate; a pressing step of pressing the pressure-sensitive adhesive layer having the adjusted hardness onto the breathable substrate after the hardness adjusting step, the hardness adjusting step includes a hardness increasing step of increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate, the pressure-sensitive adhesive layer having the adjusted hardness has an increased hardness region formed on a surface opposite to a surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region; The method for producing a breathable product, wherein the hardness increasing step includes a cooling step of cooling the surface of the release sheet opposite to the surface on which the pressure-sensitive adhesive layer is formed.

12. A manufacturing apparatus (P) for manufacturing a breathable product, in which a pressure-sensitive adhesive layer (N) is formed on one side of a breathable substrate (S1) having a gap on at least one side, and a release sheet (S2) is arranged on the surface side of the pressure-sensitive adhesive layer, and the release sheet is peeled off and the breathable substrate portion is attached to an object to be attached using the pressure-sensitive adhesive layer, a substrate supply means (10 to 14) for supplying the breathable substrate; a release sheet supplying means for supplying a release sheet; adhesive supply means (1, 2) for supplying an adhesive (M); an adhesive application means (3, 4) for applying the adhesive supplied from the adhesive supply means to a part of one side of the release sheet supplied from the release sheet supply means to form an adhesive layer; a hardness adjusting means (7) for adjusting the hardness of the adhesive layer so that only a portion of the adhesive layer formed on the release sheet by the adhesive application means penetrates into the gaps in the breathable substrate; a pressing means (5, 6) for pressing the breathable substrate supplied from the substrate supply means onto a pressure-sensitive adhesive layer having a hardness adjusted by the hardness adjusting means, the hardness adjusting means includes a hardness increasing means for increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate, the pressure-sensitive adhesive layer having the adjusted hardness has an increased hardness region formed on a surface opposite to a surface pressed against the breathable substrate, and the region on the surface pressed against the breathable substrate is maintained in a softened state region; The hardness increasing means comprises a cooling means for cooling the side of the release sheet opposite to the side on which the pressure-sensitive adhesive layer is formed.

13. A manufacturing apparatus (P) for manufacturing a breathable product, in which a pressure-sensitive adhesive layer (N) is formed on one side of a breathable substrate (S1) having a gap on at least one side, and a release sheet (S2) is arranged on the surface side of the pressure-sensitive adhesive layer, and the release sheet is peeled off and the breathable substrate portion is attached to an object to be attached using the pressure-sensitive adhesive layer, a substrate supply means (10 to 14) for supplying the breathable substrate; a release sheet supplying means for supplying a release sheet; adhesive supply means (1, 2) for supplying an adhesive (M); an adhesive application means (3, 4) for applying the adhesive supplied from the adhesive supply means to a part of one side of the release sheet supplied from the release sheet supply means to form an adhesive layer; a hardness adjusting means (7) for adjusting the hardness of the adhesive layer so that only a portion of the adhesive layer formed on the release sheet by the adhesive application means penetrates into the gaps in the breathable substrate; and pressing means (5, 6) for pressing the breathable substrate supplied from the substrate supply means against a pressure-sensitive adhesive layer having a hardness adjusted by the hardness adjusting means, and for integrating the release sheet and the breathable substrate, the hardness adjusting means includes a hardness increasing means for increasing the hardness of a region of the pressure-sensitive adhesive layer including a surface opposite to a surface pressed against the breathable substrate, The hardness increasing means comprises a cooling means for cooling the side of the release sheet opposite to the side on which the pressure-sensitive adhesive layer is formed.

14. the pressure-sensitive adhesive is a hot-melt pressure-sensitive adhesive, 13. The breathable product manufacturing apparatus according to claim 12, wherein the hardness adjusting means includes a metal roll (7) that engages with the release sheet on which the pressure-sensitive adhesive layer is formed and cools the release sheet.

15. 14. The breathable product manufacturing apparatus according to claim 13, wherein the cooling means includes a metal roll (7) that engages with the release sheet on which the adhesive layer is formed.

Images