Manufacturing method for functional composite sheets

Abstract

To provide a manufacturing method of a functional composite sheet, capable of fixing a functional liquid to be sprayed to a sheet so as to improve a yield, and controlling a fixation position of the functional liquid in a conveyance step of the sheet.SOLUTION: A manufacturing method of a functional composite sheet for manufacturing a functional composite sheet 1 which holds a functional liquid 31 between adhered two layer sheets 110, 120 includes the steps of: an adhesive application step of applying an adhesive 21 to the one surface of the first sheet 110; a liquid spray step of spraying the functional liquid 31 to the first sheet 110; and an adhesion step of joining the first sheet 110 and the second sheet 120. In the liquid spray step, the functional liquid 31 is sprayed to the one surface side of the first sheet 110 while sucking air 33 from the other surface side of the first sheet 110.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a functional composite sheet.

Background Art

[0002] Conventionally, as a functional liquid coating method in sheet processing, a direct coating method, a roll transfer method, a spray spraying method, etc. are known. Such various coating methods may be used in the manufacture of heat generating tools, etc. manufactured by changing the type of fragrance used for each product for the purpose of improving the user's feeling of use.

[0003] Among the above various methods, the spray spraying method has an advantage that since the coating device does not directly touch the sheet, contamination of the device can be suppressed compared to other methods. In addition, it is possible to coat a functional liquid over a wide area of the sheet, and moreover, the functional liquid can penetrate in the sheet thickness direction. Therefore, a method of spraying a functional liquid onto a sheet by a spraying device has been proposed (see, for example, Patent Documents 1 to 3).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0005] When spraying a functional liquid onto a sheet, since the functional liquid is atomized and sprayed, there is a case where the functional liquid does not completely adhere to the sheet and scatters around the spraying position. Therefore, there is room for improvement from the viewpoint of controlling coating in the case of fine coating ranges such as yield, intermittent coating, and coating width.

[0006] The present invention relates to a method for manufacturing a functional composite sheet in which a functional liquid to be sprayed is fixed to the sheet in a way that improves yield during the sheet transport process, and the fixing position of the functional liquid can be controlled. [Means for solving the problem]

[0007] This invention relates to a method for manufacturing a functional composite sheet. The manufacturing method preferably includes an adhesive application step in which the adhesive is applied to one side of the long first sheet while the first sheet is being transported. Preferably, this manufacturing method includes a liquid spraying step in which the functional liquid is sprayed toward the one surface to which the adhesive has been applied in the adhesive application step, thereby retaining the functional liquid on the first sheet. The manufacturing method preferably includes an bonding step of joining a first sheet holding the functional liquid and a second sheet using the adhesive applied to the first sheet. In the adhesive application step, it is preferable to apply the adhesive in such a way that there are areas where the adhesive is applied and areas where the adhesive is not applied. In the liquid spraying process, it is preferable to spray the functional liquid toward the one side of the first sheet while drawing air from the other side of the first sheet. [Effects of the Invention]

[0008] According to the present invention, in the sheet conveying process, a functional liquid can be fixed to the sheet in a way that improves yield, and the fixing position of the functional liquid can be easily controlled. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is a schematic diagram illustrating one embodiment of the method for manufacturing the functional composite sheet of the present invention. [Figure 2]Figure 2 is a cross-sectional view showing the process of spraying a functional liquid onto the first sheet while suctioning air, and then bonding it to the second sheet. [Figure 3] Figures 3(a) and (b) are schematic cross-sectional views showing the structure of the first sheet with various degrees of fiber contact angle. [Figure 4] Figures 4(a) to 4(c) are schematic plan views illustrating various methods for removing trim from a laminated sheet. [Figure 5] This graph shows the fragrance retention rate in the functional composite sheets obtained in the examples and comparative examples. [Modes for carrying out the invention]

[0010] The present invention will be described below with reference to the drawings, based on its preferred embodiments. Figures 1 and 2 show an example of a manufacturing apparatus suitably used in the manufacturing method of the present invention. In the manufacturing apparatus 10 of the embodiment shown in these figures, a long first sheet 110, which is a component of the functional composite sheet 1, is processed while being continuously conveyed, and the first sheet 110 is joined with a second sheet 120, which is another component of the functional composite sheet 1, to produce a continuous laminated sheet 100. The produced laminated sheet 100 is cut into individual sheets. These individual sheets are the target functional composite sheet 1.

[0011] The manufacturing apparatus 10 has an adhesive application section 20, a liquid spray section 30, a suction section 40, a sheet bonding section 50, a trim cutting section 60, and a trim recovery section 70, all aligned along the conveying direction R of the first sheet 110. However, the liquid spray section 30 and the suction section 40 are located at the same position along the conveying direction R of the first sheet 110. The following describes each part of the manufacturing apparatus 10.

[0012] The adhesive application section 20 includes an adhesive application device 22 that applies adhesive 21 to the first sheet 110.

[0013] The liquid spraying section 30 has a liquid spraying device 32 that sprays a functional liquid 31 onto the first sheet 110. For example, a two-fluid air spray device is used as the liquid spraying device 32. A two-fluid air spray device is generally a spraying device that has a nozzle that mixes and sprays a liquid and a gas, and has a structure that mixes the liquid and gas inside the nozzle. It is not prohibited to use other liquid spraying devices instead of the two-fluid air spray device as the liquid spraying device 32. For example, an ultrasonic spray may be used as the liquid spraying device. Regardless of the type of liquid spraying device used, the liquid spraying device is installed at a distance from the first sheet 110. That is, the liquid spraying device and the first sheet 110 are in a non-contact state. Applying the functional liquid 31 to the first sheet 110 using the liquid spraying device has technical significance in that the liquid spraying device is less likely to be contaminated. It also has technical significance in that the functional liquid 31 can be applied over a wide area and that the functional liquid 31 can easily penetrate the first sheet 110 in the thickness direction.

[0014] The suction section 40 has a suction device 41 for sucking in air 33. For example, a vacuum conveyor can be used as the suction device 41. A vacuum conveyor generally consists of an endless belt 41a that is breathable and a suction box 41b installed in the circular track of the endless belt 41a that circulates around it. As the endless belt 41a, for example, a wire mesh belt made of a woven fabric of metal wire or synthetic resin wire can be used. The suction box 41b has a structure that allows air 33 to be sucked in from the surface facing the liquid spraying device 32. As mentioned above, the suction section 40 is positioned opposite the liquid spraying section 30 with the first sheet 110 in between. Various suction devices can be used as the suction device 41. In particular, by using a vacuum conveyor as the suction device to transport the sheet and suck in air simultaneously, it is possible to efficiently suck in air while suppressing disturbances and wrinkles in the sheet transport.

[0015] In the sheet bonding section 50, the first sheet 110 and the second sheet 120, which are both conveyed in the same direction R, are overlapped and bonded together by the adhesive 21. For this purpose, a pair of nip rolls (not shown) for sandwiching the overlapped first sheet 110 and second sheet 120 may be arranged in the sheet bonding section 50.

[0016] In the trimming and cutting section 60, a part of the laminated sheet 100 formed by bonding the first sheet 110 and the second sheet 120 together is cut off. For this purpose, the trimming and cutting section 60 has a cutting device 61. As the cutting device 61, for example, a combination of a cutter roll 62 and an anvil roll 63 is used. In this case, the cutter roll 62 and the anvil roll 63 are arranged at positions facing each other with the laminated sheet 100 sandwiched therebetween. In FIG. 1, the laminated sheet 100 is separated into individual sheets by the cutting device 61, but instead, the trimming and excision process and the sheet cutting process may be performed sequentially.

[0017] The trim recovery section 70 has a trim recovery device 71 for recovering the trim 72 generated in the above-described trimming and cutting section 60.

[0018] Next, a preferred embodiment of the manufacturing method of the present invention will be described by taking as an example a method of manufacturing the functional composite sheet 1 using the above-described manufacturing apparatus 10. The manufacturing method of the functional composite sheet 1 of this embodiment includes an adhesive application step, a liquid spraying step, and an adhesion step in this order.

[0019] In the adhesive application process, as shown in Figure 1, the long first sheet 110 is conveyed in one direction R, and the adhesive 21 is applied to one side of the first sheet 110 to which the functional liquid 31 described later is to be sprayed (hereinafter, this side is also referred to as the "first side") F1 by the adhesive application device 22 installed in the adhesive application section 20. Specifically, along the conveying direction R of the first sheet 110, the adhesive 21 is applied to the first side F1 of the first sheet 110 in a predetermined application pattern, either continuously or intermittently, so that an adhesive-coated area 111 where the adhesive 21 is applied and an adhesive-uncoated area 112 where the adhesive 21 is not applied are created.

[0020] In the liquid spraying process, as shown in Figure 2, the functional liquid 31 is sprayed toward the first surface F1, which is the surface to which the adhesive 21 was applied in the adhesive application process, and the functional liquid 31 is held by the first sheet 110. Specifically, the functional liquid 31 is sprayed onto the first surface F1 of the first sheet 110 while it is being transported by a liquid spraying device 32 such as a two-fluid air spray device. Simultaneously with or prior to this operation, the suction box 41b, which is a suction device 41, is activated to suck air 33 from the other surface (hereinafter referred to as the "second surface") F2 side of the first sheet 110.

[0021] When spraying the functional liquid 31 onto the first surface F1 of the first sheet 110, air 33 is drawn in from the second surface F2 side of the first sheet 110, generating airflows with different suction forces between the adhesive-coated area 111 and the non-adhesive-coated area 112. Specifically, the non-adhesive-coated area 112, where no adhesive is applied, generates an airflow with a higher suction force than the adhesive-coated area 111, where the adhesive coating layer obstructs airflow. As a result, fine particles of the functional liquid 31 sprayed from the liquid spraying device 32 selectively adhere to the non-adhesive-coated area 112, which has a higher suction force. This allows control over the coating range of the functional liquid 31 continuously sprayed from the liquid spraying device 32, enabling concentrated adhesion of the functional liquid 31 to the non-adhesive-coated area 112. Since unintended adhesion of the functional liquid to the adhesive-coated area 111 may reduce the adhesive performance of the adhesive, concentrated adhesion of the functional liquid 31 to the non-adhesive-coated area 112 is of great technical significance. Furthermore, when spraying the functional liquid 31 onto the first surface F1 of the first sheet 110, it is possible to control the process by drawing in air 33 from the second surface F2 side of the first sheet 110, thereby preventing the functional liquid 31 from adhering to the portion corresponding to the trim 72 that is cut off by the trim cutting section 60 described above. This has significant technical importance from the standpoint of reducing the loss of the functional liquid 31.

[0022] Furthermore, according to this embodiment, by sucking air 33 from the second surface F2 side, which is the back surface of the first sheet 110, even when a two-fluid spray, which generally has a high liquid flow velocity and is prone to causing the sheet to flutter and the sprayed liquid to scatter, is used as the liquid spraying device 32, there is an advantage in that the fluttering of the sheet 110 and the scattering of the functional liquid 31 can be suppressed. This effect is particularly noticeable when a vacuum conveyor is used.

[0023] The various advantages described above that are achieved by this embodiment are only realized when the liquid spraying step is performed after the adhesive application step. In other words, if the adhesive application step is performed after the liquid spraying step, the various advantages described above that are achieved by this embodiment will not be realized, or will be realized to a very low degree. However, in this invention, there is no preclude adding a step of applying adhesive after the liquid spraying step.

[0024] The suction of air 33 from the back of the first sheet 110 by the suction device 41 may be continuous or intermittent. For example, if the adhesive-coated area 111 and the non-adhesive-coated area 112 described above are formed on the first sheet 110, the suction can be controlled on and off by stopping the suction when the adhesive-coated area 111 passes over the suction device 41, and performing suction when the non-adhesive-coated area 112 passes over the suction device 41. However, since the adhesive-coated area 111 is generally a part with low or no air permeability, even if the suction device 41 is operated when the adhesive-coated area 111 passes over the suction device 41, suction of air 33 through the adhesive-coated area 111 is unlikely to occur, so there is no problem with continuous suction regardless of whether it is the adhesive-coated area 111 or the non-adhesive-coated area 112. In other words, the present invention has technical significance in that it allows for the selective application of functional liquids even when continuous suction, which is a simpler control than intermittent suction, is performed.

[0025] There are no particular restrictions on the type of functional liquid 31; an appropriate one is selected according to the specific application of the functional composite sheet. Examples of functional liquids 31 include liquids containing fragrances, as well as liquids containing oils that control hydrophilicity and antibacterial components. When the functional liquid 31 contains a fragrance, there is generally an inconvenience in that the fragrance's scent can easily transfer to the manufacturing apparatus 10. However, in this manufacturing method, since the suction device 41 is used to draw in air 33, the scattering of the sprayed fragrance into the surroundings is suppressed, and the fragrance is also removed by suction from the suction device 41, thus having the advantage of being less prone to such inconveniences.

[0026] Preferably, the fiber contact angle of the fibers constituting the first sheet 110 is controlled. Specifically, it is preferable that the fiber contact angle of the first sheet 110 is smaller on the first surface F1 side to which the functional liquid 31 is sprayed compared to the second surface F2 side to which the functional liquid 31 is not sprayed. In the liquid spraying process, spraying the functional liquid 31 on the first surface F1 side, where the fiber contact angle is small, makes it difficult for the functional liquid 31 adhering to the first sheet 110 to penetrate to the second surface F2 side, thereby suppressing the bleed-through of the functional liquid 31, and also makes it possible to easily wet and spread the functional liquid 31 on the first surface F1 side of the first sheet 110. In this specification, the fiber contact angle refers to the contact angle with water measured for the fibers constituting the first sheet 110. The measurement method will be described later.

[0027] Figures 3(a) and (b) show cross-sectional views along the thickness direction of various first sheets 110 in which the contact angle of the constituent fibers is controlled. In the embodiment shown in Figure 3(a), the first sheet 110 is constructed by overlapping two layers, each containing fiber A and fiber B, which have different fiber contact angles. Of the two layers of sheet 110, fiber A in the upper first layer 115A has a smaller fiber contact angle than fiber B in the lower second layer 115B. In the figure, the surface of the first layer 115A is the first surface F1, and the surface of the second layer 115B is the second surface F2.

[0028] In the embodiment shown in Figure 3(b), the first sheet 110 has a single-layer structure, and the fiber contact angle changes in a step-like manner along its thickness direction. Specifically, with the approximate center along the thickness direction of the first sheet 110 as the boundary, the fiber contact angle on the upper first surface F1 side is smaller in a step-like manner than on the lower second surface F2 side.

[0029] The method for measuring the fiber contact angle is as follows: The automatic contact angle meter MCA-J (product name) manufactured by Kyowa Interface Science Co., Ltd. is used as the measuring device. Deionized water is used to measure the fiber contact angle. The amount of liquid ejected from an inkjet-type water droplet ejection unit (CTC-25 pulse injector manufactured by Cluster Technology Co., Ltd., with an ejection unit pore diameter of 25 μm) is set to 10 picoliters, and water droplets are dropped directly onto the fibers. The dropping process is recorded by a high-speed recording device connected to a horizontally mounted camera. From the perspective of later image analysis, a personal computer with a built-in high-speed capture device is preferred as the recording device. In this measurement, images are recorded every 17 msec. In the recorded video, the first image in which a water droplet lands on a fiber removed from the nonwoven fabric is analyzed using the attached software FAMAS (software version 2.6.2, analysis method: droplet method, analysis method: θ / 2 method, image processing algorithm: non-reflection, image processing image mode: frame, threshold level: 200, curvature correction: none), and the angle between the surface of the water droplet that touches the air and the fiber is calculated and defined as the fiber contact angle. If the fibers extracted from the first sheet 110 are longer than 2 mm, they are cut to a length of 2 mm, and the fibers are placed on the sample stage of the contact angle meter and kept horizontal. Three different contact angles are measured for each fiber, and the average value (rounded to two decimal places) is defined as the fiber contact angle.

[0030] To adjust the fiber contact angle of the constituent fibers of the first sheet 110, an appropriate hydrophilic agent can be applied to the surface of the fibers, or an appropriate hydrophilic agent can be kneaded into the resin that constitutes the fibers.

[0031] In the bonding process, the first sheet 110, to which adhesive 21 has been applied and functional liquid 31 has been sprayed, is directly joined to the second sheet 120 to obtain a long laminated sheet 100 that retains the functional liquid 31. Specifically, as shown in Figure 1, at the sheet bonding portion 50, the first surface F1 of the first sheet 110 that retains the functional liquid 31 and one surface of the second sheet 120 are joined in direct contact without the use of other components. As described above, since the functional liquid is selectively applied to the areas where the adhesive is not applied, the effect of the present invention, in which the adhesive performance of the adhesive is ensured when joining the first sheet and the second sheet, becomes particularly pronounced in this process.

[0032] Once a long laminated sheet 100 is obtained through the bonding process, the next step is to trim the laminated sheet 100. Trimming involves removing and separating a portion of the laminated sheet 100, specifically, an unnecessary portion (i.e., trim) 72 from the target functional composite sheet 1. In the trim removal process, as shown in Figure 1, a predetermined portion (trim 72) of the laminated sheet 100 during transport is intermittently cut at the trim removal section 60 to obtain the desired functional composite sheet 1. The removed trim 72 is recovered by the recovery device 71.

[0033] In the trim removal process, it is preferable that the removal area of ​​the laminated sheet 100 includes at least a portion of the adhesive application area 111 on the first sheet 110. In particular, it is preferable that the adhesive application area 111 is formed to span the removal area in the trim removal process and the other areas. This makes it possible to prevent the functional liquid 31 from adhering to the removal area and to join the first sheet 110 and the second sheet 120 in a single joining process. Another advantage is that the trim of the first sheet and the trim of the second sheet do not separate and can be recovered as a single unit.

[0034] Various combinations of the formation pattern of the adhesive application area 111 for bonding the first sheet 110 and the second sheet 120, and the pattern of the trim cutting area can be cited. Some examples of these are shown in Figures 4(a) to (c). In these figures, the symbol R indicates the direction of sheet transport.

[0035] In the embodiment shown in Figure 4(a), adhesive is applied in a substantially rectangular shape to the peripheral area along the long and short sides of the first sheet 110 to form an adhesive application area 111. Next, the functional liquid 31 is sprayed onto the adhesive-free area 112 to form the liquid spray area 113. Next, the second sheet 120 is placed on top of the first sheet 110 to form a laminated sheet 100. Then, a roughly rectangular area including the liquid spray area 113 and part of the adhesive application area 111 is punched out (shown by dashed lines in Figures 4(a) to (c)), and the remaining portion of the adhesive application area 111, the cut-out area 116, is removed.

[0036] In the embodiment shown in Figure 4(b), first, adhesive is applied to the peripheral area along the long side of the first sheet 110 to form a pair of strip-shaped adhesive application regions 111. Next, the functional liquid 31 is sprayed onto the non-adhesive area 112, which is the area sandwiched between the pair of adhesive-coated areas 111, to form a liquid-sprayed area 113. Next, the second sheet 120 is placed on top of the first sheet 110 to form a laminated sheet 100. Then, the cut-off area 116, which is the outermost part of each adhesive application area 111 in the width direction and extends in the longitudinal direction, is cut off.

[0037] In the embodiment shown in Figure 4(c), first, adhesive is applied to the peripheral areas of all four sides of the first sheet 110 in a substantially rectangular shape, and adhesive is also applied to the central area in a direction perpendicular to the conveying direction R, along the conveying direction R, to form an adhesive-coated area 111. This creates two rectangular areas 112 where the adhesive is not applied. Next, the functional liquid 31 is sprayed onto the adhesive-uncoated area 112 to form two liquid spray areas 113. Next, the second sheet 120 is placed on top of the first sheet 110 to form a laminated sheet 100, and then the cut-off area 116, which is a part of the rectangular portion of the adhesive application area 111, is cut off.

[0038] Next, various materials used in the manufacturing method of the functional composite sheet 1 of the present invention will be described.

[0039] The first sheet 110 can be composed of, for example, a breathable resin film and a fiber sheet, or a laminate thereof. Examples of resin films include breathable films made of polymer materials such as polyethylene terephthalate (PET), polyester, polyethylene (PE), polypropylene, cellophane, nylon, polyvinyl alcohol, polyvinyl chloride, and polycarbonate. Examples of fiber sheets include spunbond nonwoven fabrics, air-through nonwoven fabrics, spunlace nonwoven fabrics, heat-rolled nonwoven fabrics, melt-blown nonwoven fabrics, or laminated nonwoven fabrics thereof.

[0040] As described above, the preferred constituent materials for the first sheet 110 are as described above. As for the second sheet 120, in the bonding process described above, it is preferable that the second sheet 120 is a sheet containing pulp fibers on its outer surface, from the viewpoint of facilitating good absorption and retention of the functional liquid 31 on the second sheet 120 side and preventing the functional liquid 31 from seeping through from the first sheet 110. In particular, it is preferable that at least the outer surface of the second sheet 120 that comes into contact with the first sheet 110 contains pulp fibers. Pulp fibers are composed of cellulose, and cellulose molecules contain many highly lipophilic methylidine groups. Since methylidine groups have a high affinity for the aromatic components of fragrances, the presence of pulp fibers on the outer surface of the second sheet 120 allows the coated functional liquid 31 to be well retained when it is a fragrance. The second sheet 120 can be used as a standalone material by incorporating pulp fibers into its outer surface. It is also preferable to use a laminated sheet of non-permeable resin film and paper as the second sheet 120. In particular, when using the functional composite sheet 1 as a material for manufacturing the heating device described later, using the second sheet 120 in this form makes it easier to appropriately control the heat generation of the heating element contained in the heating device by making the second sheet 120 non-permeable.

[0041] Examples of adhesives 22 used to bond the first sheet 110 and the second sheet 120 include water-based adhesives and organic adhesives. The choice of adhesive is appropriately determined according to the constituent materials of the first sheet 110 and the second sheet 120.

[0042] The fragrances that may be included in the functional liquid 31 may contain aromatic components that volatilize into the atmosphere under atmospheric pressure. These aromatic components may be those whose fragrance can be perceived under normal temperature and pressure conditions. Examples of aromatic components that make up fragrances include those listed in "Synthetic Fragrance Chemistry and Product Knowledge" (edited by the Synthetic Fragrance Editorial Committee, Chemical Daily Co., Ltd., revised and expanded edition, December 20, 2016). Specifically, aromatic components include terpene hydrocarbons, aldehydes, phenols, lactones, and the like. Examples of terpene hydrocarbons include myrcene, farnesene, pinene, limonene, camphene, phellandrene, terpinene, terpinolene, p-cymene, cedrene, and caryophyllene. Examples of aldehydes include hexyl cinnamic aldehyde, 2-methyl-3-(4-tert-butylphenyl)-propanal, 4-(4-hydroxy-4-methylpentyl)-3-cyclohexene-1-carboxyaldehyde, and vanillin. Examples of phenols include aromatic alcohols such as anethole and eugenol. Aromatic alcohols such as anethole or eugenol include benzyl alcohol, phenylethyl alcohol, pamplefleur (2-methyl-4-phenylpentanol), dimethylbenzylcarbinol, and phenylhexanol (3-methyl-5-phenylpentanol). Examples of lactones include γ-nonalactone and γ-undecalactone. Furthermore, the term "fragrance" includes "a combination of fragrance materials composed of multiple fragrances (fragrance composition), which has been diluted and adjusted with a solvent." For example, a fragrance composition having scents similar to rose, lavender, jasmine, or ylang-ylang can be used as the fragrance.

[0043] The functional composite sheet 1 manufactured by the above method may be used alone, or it may be further processed to manufacture other articles. For example, a heating device may be manufactured using the functional composite sheet 1 manufactured by the above method. Examples of such heating devices include so-called face mask type and eye mask type devices. This type of heating device can be used to apply steam heated to a predetermined temperature to the skin of a target area, such as a person's nose and mouth, or both eyes or areas near them, by placing it in contact with the target area.

[0044] A heating device typically comprises a surface sheet that faces the object to be heated, such as the user's skin, when the heating device is in use, and a back sheet located on the side furthest from the object to be heated. When a heating device with these sheets is manufactured using a functional composite sheet 1, the first sheet 110 and the second sheet 120 described above can be used as the surface sheet and the back sheet.

[0045] A heating device typically has a heating element capable of generating steam in conjunction with heat generation. The heating element is configured to generate steam heated to a predetermined temperature in conjunction with heat generated by an oxidation reaction with oxygen in the air. In detail, the heating element includes an oxidizable metal that generates heat due to an oxidation reaction with oxygen in the air, activated carbon, and optionally an electrolyte and water.

[0046] When manufacturing a heating device using a functional composite sheet 1, the manufacturing method preferably includes a step of supplying a heating element after performing a liquid spraying step. More specifically, after spraying the functional liquid 31 onto the first sheet 110 according to the procedure described above, it is preferable to intermittently arrange heating elements in the form of heating sheets or heating compositions at predetermined intervals along the conveying direction R between the first sheet 110 and the second sheet 120, which are being conveyed along the conveying direction R, prior to bonding the first sheet 110 and the second sheet 120. For example, in Figure 4(c), it is preferable to arrange the heating elements in the adhesive-free area indicated by reference numeral 112. Such a method for manufacturing a heating device is described, for example, in Figure 10 of the aforementioned Patent Document 3.

[0047] When manufacturing a heating device using the functional composite sheet 1, it is preferable that the manufacturing apparatus 10 further includes an ear loop forming section. The ear loop forming section is for supplying a long, strip-shaped ear loop sheet raw material to the side of the surface sheet where the heating element is not placed, in order to form an ear loop made of sheet material.

[0048] Although the present invention has been described above based on its preferred embodiments, the present invention is not limited to the above embodiments. For example, the functional liquid 31 can be applied intermittently along the transport direction R, but is not limited to this, and may be applied in the form of stripes (bands), scattered dots, checkerboard patterns, etc. [Examples]

[0049] The present invention will be described in more detail below with reference to examples. However, the scope of the present invention is not limited to these examples.

[0050] [Examples 1 to 9] In Examples 1 to 9, the functional composite sheet 1 was manufactured using the apparatus shown in Figures 1 and 2. However, for practical reasons, trimming was not performed. Therefore, strictly speaking, these examples should be called "model examples." As for the first sheet 110, the basis weight is 30 g / m². 2A PET / PE mixed nonwoven fabric was used. The second sheet was 120, with a basis weight of 60 g / m². 2 A PET / PE mixed nonwoven fabric was used. HM-Disposable Melt ME716E (manufactured by Henkel Co., Ltd.) was used as the adhesive 21. A fragrance (oil-soluble fragrance with a viscosity of 20 mPa·s at 25°C) was used as the functional liquid 31. Adhesive 21 was applied to the first surface F1 of the first sheet 110 in the pattern shown in Figure 4(a), while the first sheet 110 was being transported at a transport speed of 30 m / min so that a liquid spray area 113 was formed on the first sheet 110. Next, functional liquid 31 was continuously sprayed using a two-fluid air spray device, spanning both the adhesive-coated area and the non-adhesive-coated area. The spray air pressure was as shown in Table 1 below. The length of the adhesive-coated area 111 along the transport direction R was set to 100 mm. Along with the spraying of the functional liquid 31, air was sucked from the second surface F2 side of the first sheet 110 using a vacuum conveyor. The suction pressure was as shown in Table 1 below. A laminated sheet 100 was obtained by overlapping the second sheet 120 onto the first surface F1 of the first sheet 110. This laminated sheet 100 was cut into a predetermined shape to obtain the desired functional composite sheet 1. The wet weight W2 of the obtained functional composite sheet 1 was measured, and then it was dried at 70°C for 3 days. After that, the dry mass W1 of the functional composite sheet 1 was measured, and the mass W3 of the fragrance fixed to the functional composite sheet 1 was calculated by subtracting W1 from the wet mass W2 of the functional composite sheet 1 before drying. The fragrance fixation rate was calculated from the mass W3 of the fragrance fixed to the functional composite sheet 1 and the value obtained by dividing the pre-measured fragrance spray rate per minute by the number of functional composite sheets processed per minute. The results are shown in Figure 5. The average value of 5 samples was calculated and that value was used as the fixation rate.

[0051] [Table 1]

[0052] [Comparative Example 1] A functional composite sheet 1 was obtained in the same manner as in Example 1, except that air was not drawn in from the second side F2 of the first sheet 110. The fragrance fixation rate on this functional composite sheet 1 was measured in the same manner as in Example 1. The results are shown in Figure 5.

[0053] As is clear from the results shown in Figure 5, each example shows that the fragrance can be fixed to the sheet at an extremely high rate. In Comparative Example 1, the functional liquid 31 scattered, resulting in significant loss. [Explanation of Symbols]

[0054] 1. Functional composite sheet 21 Adhesive 31 Functional liquids 33 Air 40 Suction part 50 Sheet bonding section 110 Sheet 1 F1 front page F2 2nd side 111 Adhesive application area 112 Areas where adhesive is not applied 120, 2nd seat

Claims

1. The process involves applying adhesive to one side of a long, rectangular first sheet while the sheet is being transported, and The adhesive application step involves spraying a functional liquid onto one of the surfaces to which the adhesive has been applied, thereby causing the first sheet to retain the functional liquid; A method for manufacturing a functional composite sheet, comprising an bonding step of joining a first sheet holding the functional liquid and a second sheet using the adhesive applied to the first sheet, In the adhesive application step, the adhesive is applied such that there are areas where the adhesive is applied and areas where the adhesive is not applied. A method for manufacturing a functional composite sheet, wherein in the liquid spraying step, the functional liquid is sprayed toward the coated area and the uncoated area on one side of the first sheet while air is drawn in from the other side of the first sheet toward the coated area and the uncoated area.

2. The bonding process involves bonding a first sheet and a second sheet to obtain a laminated sheet, and the process includes a trimming step in which a portion of the laminated sheet is cut off and recovered. The method for manufacturing a functional composite sheet according to claim 1, wherein the trim cutting step includes at least a portion of the area where the adhesive is applied in the first sheet.

3. The method for manufacturing a functional composite sheet according to claim 2, wherein in the adhesive application step, the area to which the adhesive is applied is formed to span across the trimming area and the other area in the trimming step.

4. A method for manufacturing a functional composite sheet according to any one of claims 1 to 3, wherein in the liquid spraying step, a two-fluid air spray device is used as the spraying device for the functional liquid.

5. A method for manufacturing a functional composite sheet according to any one of claims 1 to 3, wherein in the liquid spraying step, a vacuum conveyor is used as a suction device for sucking the air from the other side of the first sheet.

6. As the second sheet, a sheet containing pulp fibers on its outer surface is used. A method for manufacturing a functional composite sheet according to any one of claims 1 to 3, wherein in the bonding step, the outer surface of the second sheet is bonded to one surface of the first sheet so as to be in direct contact with it.

7. A method for manufacturing a functional composite sheet according to any one of claims 1 to 3, wherein, in the state before spraying the functional liquid, the fiber contact angle of the first sheet is smaller on one side than on the other side.

8. A method for manufacturing a heating device including a functional composite sheet and a heating element, A method for manufacturing a heating device, comprising the step of obtaining the functional composite sheet by the method for manufacturing a functional composite sheet described in any one of claims 1 to 3.

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