Method for producing shaped fiber sheet and fiber product

Abstract

The present invention comprises: a step for bending a long fiber sheet (20) so that the fiber sheet (20) is wrinkled in the width direction so as to include lengthwise protruding sections (20a), while the fiber sheet (20) is being conveyed; a step for conveying the fiber sheet (20), which has been bent so as to be wrinkled in the width direction, between a pair of continuous tracks (13a, 16a) that drive in the conveyance direction, and thus partially pressing the lengthwise protruding sections (20a) by interlocking of shaped members (14, 17) that are provided in rows along the conveyance direction on each of the pair of continuous tracks (13a, 16a); and a step for heating the fiber sheet (20) that has been bent so that protruded / depressed shapes are exhibited by partially pressing the lengthwise protruding sections (20a).

Description

Method for manufacturing shaped fiber sheet, shaped fiber sheet and fiber product

[0001] The present invention relates to a method for producing a shaped fiber sheet, a shaped fiber sheet, and a fiber product.

[0002] Conventionally, shaped fiber sheets in which a textured shape is formed on a fiber sheet and methods for manufacturing such shaped fiber sheets have been known. For example, a method for manufacturing a shaped fiber sheet is known in which a flat long-fiber nonwoven fabric (fiber sheet) is processed to be three-dimensionally bulky in the thickness direction while substantially maintaining the thickness of the nonwoven fabric, thereby obtaining a long-fiber nonwoven fabric (shaped fiber sheet) in which irregular, textured wrinkles with extreme drop shapes are formed (see Patent Document 1).

[0003] In the manufacturing method of Patent Document 1, wrinkle-free long-fiber nonwoven fabric is packed into a bag and then moistened with heat (hot water or steam at 60°C or higher), thereby forming wrinkles in the long-fiber nonwoven fabric.

[0004] Patent No. 5752775

[0005] However, the shaped fiber sheet manufactured by the manufacturing method of Patent Document 1 has problems such as irregular wrinkles, the shape, number, and bulk of the uneven shapes being formed randomly, the outer shape cannot be defined, it is difficult to spread, the straight lines of the periphery are lost, there is a large loss during cutting, it is difficult to work with during sewing, etc. In addition, the manufacturing method of Patent Document 1 is not suitable for continuous production, and there is a problem that the manufacturing efficiency is poor.

[0006] In other words, the present invention aims to provide a method for producing a shaped fiber sheet with high production efficiency, and a shaped fiber sheet and fiber product that are easy to use.

[0007] The method for manufacturing a shaped fiber sheet according to the present invention includes the steps of: conveying a long fiber sheet while bending the fiber sheet so that it wrinkles in the width direction so as to include longitudinal peaks and / or longitudinal valleys extending longitudinally along the conveying direction; conveying the fiber sheet bent so that it wrinkles in the width direction between endless tracks that drive along the conveying direction on both sides of the thickness of the fiber sheet, thereby partially pressing the longitudinal peaks and / or the longitudinal valleys by engaging shaping members arranged in a row on the endless tracks along the conveying direction; and heating the fiber sheet that has been bent so that it has an uneven shape by partially pressing the longitudinal peaks and / or the longitudinal valleys.

[0008] The shaped fiber sheet of the present invention is a shaped fiber sheet having an area in which multiple regular uneven shapes are formed, wherein the elongation rate in the area is 20% or more, and the ratio of the projected area of ​​the shaped fiber sheet to the surface area of ​​the fiber sheet before the uneven shapes are formed is 80% or less.

[0009] The textile product according to the present invention is characterized in that it uses a shaped fiber sheet manufactured by the manufacturing method for a shaped fiber sheet according to the present invention as padding.

[0010] According to the manufacturing method of a shaped fiber sheet, the shaped fiber sheet, and the fiber product of the present invention, it is possible to provide a manufacturing method of a shaped fiber sheet with high manufacturing efficiency, and a shaped fiber sheet and fiber product that are easy to use.

[0011] 1 is an explanatory diagram showing an example of a manufacturing apparatus for a shaped fiber sheet according to an embodiment of the present invention. FIG. 1 is an explanatory diagram showing an example of the configuration of a manufacturing apparatus for a shaped fiber sheet according to an embodiment of the present invention. FIG. 2 is an explanatory diagram showing an example of a process for bending a fiber sheet according to an embodiment of the present invention in the width direction. FIG. 3 is an explanatory diagram showing an example of a process for bending a fiber sheet according to an embodiment of the present invention in the width direction. FIG. 4 is an explanatory diagram showing an example of a process for bending a fiber sheet according to an embodiment of the present invention in the width direction. FIG. 5 is an explanatory diagram showing an example of a process for bending a fiber sheet according to an embodiment of the present invention in the width direction. FIG. 6 is an explanatory diagram showing an example of a process for bending a fiber sheet according to an embodiment of the present invention in the width direction. FIG. 7 is an explanatory diagram showing an example of a process for forming a concave-convex shape in a fiber sheet according to an embodiment of the present invention. FIG. 8 is an explanatory diagram showing an example of a process for forming a concave-convex shape in a fiber sheet according to an embodiment of the present invention. FIG. 9 is an explanatory diagram showing an example of a process for forming a concave-convex shape in a fiber sheet according to an embodiment of the present invention. FIG. 10 is a front oblique view showing an example of a shaped fiber sheet according to an embodiment of the present invention. FIG. 11 is an explanatory diagram showing an example of a manufacturing method for a shaped fiber sheet according to a modified embodiment of an embodiment of the present invention. FIG. 12 is an explanatory diagram showing an example of a manufacturing method for a shaped fiber sheet according to a modified embodiment of an embodiment of the present invention. Fig. 1 is an explanatory diagram showing an example of a shaping member according to a modified example of an embodiment of the present invention. Fig. 2 is an explanatory diagram showing an example of a shaping member according to a modified example of an embodiment of the present invention. Fig. 3 is an explanatory diagram showing an example of a shaping member according to a modified example of an embodiment of the present invention. Fig. 4 is an explanatory diagram showing an example of a shaping member according to a modified example of an embodiment of the present invention. Fig. 5 is an explanatory diagram showing a comparative example of gaps when a shaped fiber sheet according to an embodiment of the present invention is used as the filling of a comforter and when a conventional heat-insulating material is used as the filling of a comforter.

[0012] Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. Figures 1 and 2 are explanatory diagrams showing an example of a shaped fiber sheet manufacturing apparatus according to this embodiment, and Figures 3 to 9 are explanatory diagrams showing an example of a shaped fiber sheet manufacturing method.

[0013] 1 and 2, the shaped fiber sheet manufacturing apparatus 1 includes a conveying path 2 for conveying a long fiber sheet, a bending unit 3 for bending the fiber sheet so as to wrinkle it in the width direction, a bending retention member 4 for retaining the bending of the fiber sheet bent so as to wrinkle it in the width direction in the bending unit 3, and a shaping unit 5 for bending the fiber sheet into an uneven shape and heating the bent fiber sheet into an uneven shape to shape it. In the bending unit 3, the fiber sheet is bent, for example, into a zigzag shape.

[0014] Examples of the fiber sheet according to this embodiment include a paper sheet, a nonwoven fabric sheet, a carbon fiber sheet, a glass fiber sheet, a natural fiber sheet, a functional fiber sheet, a metal fiber, and a cloth.

[0015] Examples of nonwoven fabrics used for the nonwoven fabric sheet include spunbond nonwoven fabrics, spunlace nonwoven fabrics, meltblown nonwoven fabrics, thermal bond nonwoven fabrics, air-through nonwoven fabrics, air-laid nonwoven fabrics, chemical bond nonwoven fabrics, and needle-punched nonwoven fabrics.

[0016] Examples of materials for the fiber sheet include synthetic fibers such as aramid fibers, glass fibers, cellulose fibers, nylon fibers, vinylon fibers, polyester fibers, polyethylene fibers, polypropylene fibers, polyolefin fibers, acrylic fibers, and rayon fibers, natural fibers such as pulp, kenaf, wool, cotton, bamboo, and hemp, and metal fibers. These may be used singly, in a mixture, in a composite, or in a mixed form.

[0017] The deflection forming unit 3 includes a plurality of rollers 7 supported on a shaft 6 extending in a width direction intersecting (e.g., perpendicular to) the conveying direction of the fiber sheet. The rollers 7 are arranged vertically and are divided into an upper roller group 8 (solid line in FIG. 1 ) arranged on the upper side and a lower roller group 9 (dotted line in FIG. 1 ) arranged on the lower side. Each roller 7 is a bicone formed by joining the bases of two truncated cones.

[0018] Furthermore, the upper roller group 8 and the lower roller group 9 have an increasing number of rollers 7 supported on their shafts from the upstream side to the downstream side of the conveying path 2. Specifically, the upper roller group 8 has one roller 7 arranged at the most upstream position. The lower roller group 9 has two rollers 7 arranged at the most upstream position. The number of rollers 7 increases by one from the upstream side to the downstream side in both the upper roller group 8 and the lower roller group 9. The rollers 7 of the upper roller group 8 and the rollers 7 of the lower roller group 9 are arranged alternately in the width direction. The rollers 7 of the upper roller group 8 are inserted into the gaps between the rollers 7 of the lower roller group 9.

[0019] The shaping section 5 includes an upper shaping device 10 that partially presses down the longitudinal peaks of the fiber sheet that has been bent so as to wrinkle in the width direction in the bending forming section 3, and a lower shaping device 11 that maintains the bulk of the longitudinal peaks of the fiber sheet that has been bent so as to wrinkle in the width direction in the bending forming section 3.

[0020] The upper shaping device 10 includes a pair of rollers 13 supported on a shaft 12 extending in the width direction perpendicular to the fiber sheet conveyance direction and aligned along the conveyance direction, and a pair of endless tracks 13a wound around both ends of each roller 13. Examples of the endless tracks 13a include belts, chains, nets, wires, ropes, threads, and strings. The rollers 13 rotate counterclockwise when viewed from the side in FIG. 1 by being driven by a motor (not shown). Other components, such as gears, sprocket gears, cams, and rims, may be used instead of the rollers 13.

[0021] A plurality of shaping members 14 are attached to the endless track 13a. The shaping members 14 are arranged in a row along the conveying direction of the fiber sheet 20 so as to intersect with the conveying direction.

[0022] In this embodiment, the shaping members 14 are arranged in a row so as to intersect at right angles with the conveying direction of the fiber sheet, but the relative angle of intersection does not have to be limited to a right angle as long as it intersects with the conveying direction of the fiber sheet.

[0023] The shaping member 14 has a rectangular plate shape that is long in the width direction perpendicular to the conveying direction of the fiber sheet, and both ends of one long side of the shaping member 14 are attached to the endless track 13a.

[0024] The other long side of the shaping member 14 has a plurality of protrusions 14a and recesses 14b alternately arranged along the width direction perpendicular to the conveying direction of the fiber sheet. The protrusions 14a and recesses 14b of each shaping member 14 are aligned in the same row in the conveying direction of the fiber sheet. As described below, when the roller 13 rotates, the endless track 13a is driven, and the shaping member 14 is driven along the conveying direction in response to the drive of the endless track 13a. The protrusions 14a of the shaping member 14 partially press down the longitudinal peaks of the fiber sheet. As described below, a flexure retention member 4 is inserted into each recess 14b to prevent interference between the shaping member 14 and the flexure retention member 4.

[0025] The lower shaping device 11 includes a pair of rollers 16 supported on a shaft 15 extending in the width direction perpendicular to the fiber sheet conveyance direction and aligned along the conveyance direction, and a pair of endless tracks 16a wound around both ends of the pair of rollers 16. Examples of the endless tracks 16a include belts, chains, nets, wires, ropes, threads, and strings. The rollers 16 rotate clockwise when viewed from the side in FIG. 1 by being driven by a motor (not shown). Note that other components such as gears, sprocket gears, cams, and rims may be used instead of the rollers 13.

[0026] A plurality of shaping members 17 are attached to the endless track 16a. The shaping members 17 are arranged in pairs along the conveying direction. Each shaping member 17 has a rectangular plate shape that is long in the width direction. Both ends of one long side of each shaping member 17 are attached to the endless track 16a.

[0027] The other long side of the shaping member 17 has a plurality of protrusions 17a and recesses 17b arranged alternately along the width direction perpendicular to the conveying direction of the fiber sheet. The protrusions 17a and recesses 17b of each shaping member 17 are aligned in the same row in the conveying direction of the fiber sheet. When the roller 16 rotates, the endless track 16a is driven, and the shaping member 17 is driven along the conveying direction in response to the drive of the endless track 16a. The protrusions 17a of the shaping member 17 maintain the bulk of the longitudinal peaks of the fiber sheet. As described below, a flexure retention member 4 is inserted into each recess 17b to prevent interference between the shaping member 17 and the flexure retention member 4.

[0028] The flexure retention members 4 are rod-shaped and extend in the conveying direction. They are arranged at regular intervals along the width direction of the fiber sheet, which is perpendicular to the conveying direction. The flexure retention members 4 are installed so as to slope downward from the upstream side to the downstream side. Note that the flexure retention members 4 may not be used depending on the uneven shape to be formed.

[0029] In addition, although an example has been given in which a pair of endless tracks 13a and endless tracks 16a are used, for example, two or more pairs of endless tracks may be used on both sides of the thickness direction of the fiber sheet 20, or the number of endless tracks may be different on one side and the other side.

[0030] Next, a method for manufacturing a shaped fiber sheet using the shaped fiber sheet manufacturing apparatus 1 configured as described above will be described with reference to FIGS.

[0031] As shown in Figures 3 to 6, in the manufacturing method of the shaped fiber sheet of this embodiment, first, while conveying a long fiber sheet 20, a process proceeds to bending the fiber sheet 20 so that it is wrinkled in the width direction so as to include longitudinal peaks 20a and / or longitudinal valleys 20b extending longitudinally along the conveying direction.

[0032] For example, this process is preferably a process in which, while conveying a long fiber sheet 20, the fiber sheet 20 is bent so as to wrinkle in the width direction so that the longitudinal peaks 20a and longitudinal valleys 20b extending longitudinally along the conveying direction are arranged alternately along the width direction perpendicular to the conveying direction.

[0033] In this step, it is preferable that the fiber sheet 20 passes through a gap between the rollers 7 of the upper roller group 8 and the rollers 7 of the lower roller group 9 in the deflection forming unit 3. When the fiber sheet 20 passes through a gap between the rollers 7 of the upper roller group 8 and the rollers 7 of the lower roller group 9, the fiber sheet 20 conforms to the shape of the rollers 7. As a result, the fiber sheet 20 is drawn toward the center in the width direction. Since a plurality of rollers 7 are arranged in the conveyance direction and the width direction, the fiber sheet 20 can be deflected so as to wrinkle in the width direction, so that longitudinal peaks 20a and longitudinal valleys 20b extending longitudinally along the conveyance direction are alternately arranged in the width direction.

[0034] In this process, an example is given in which the fiber sheet 20 is bent so as to wrinkle in the width direction so as to include the longitudinal peaks 20a and the longitudinal valleys 20b, but the fiber sheet 20 may also be bent so as to wrinkle in the width direction so as to include either the longitudinal peaks 20a or the longitudinal valleys 20b.

[0035] Next, the fiber sheet 20 preferably proceeds to a step of maintaining the bending of the fiber sheet 20 that has been bent so as to wrinkle in the width direction. In this step, bending maintaining members 4 are inserted into the longitudinal valleys. This makes the longitudinal valleys 20b deeper, and also maintains the bending of the longitudinal valleys 20b as well as the bending of the longitudinal peaks 20a.

[0036] In this case, although not specifically shown, the deflection shape of the longitudinal peaks 20a and the longitudinal valleys 20b along the width direction may be adjusted from a sine wave shape as shown in FIG. 5 to a non-sinusoidal wave shape such as a rectangular wave shape.

[0037] Next, the fiber sheet 20, which has been bent so as to be wrinkled in the width direction, is transported between a pair of endless tracks 13a, 16a that are driven along the transport direction, and the process proceeds to a step in which the longitudinal peaks 20a and / or longitudinal valleys 20b are partially pressed by the engagement of the shaping members 14, 17 that are arranged in a row along the transport direction on each of the pair of endless tracks 13a, 16a.

[0038] In this process, the fiber sheet 20 is transported to the shaping unit 5. In the shaping unit 5, the motor of the upper shaping device 10 drives the roller 13 to rotate counterclockwise in a side view in Fig. 1. This drives the endless track 13a along the transport direction, and the shaping member 14 moves along the transport direction in accordance with the drive of the endless track 13a.

[0039] Meanwhile, in the shaping section 5, the roller 16 is rotated clockwise as viewed from the side in Fig. 1 by the driving of the motor of the lower shaping device 11. As a result, the endless track 16a is driven along the conveying direction, and the shaping member 17 moves along the conveying direction in accordance with the driving of the endless track 16a.

[0040] The shaping member 14 and the shaping member 17 move in synchronization with the conveyance of the fiber sheet 20. In addition, when the shaping member 14 moves to a position where it protrudes toward the lower shaping device 11 during the movement of the shaping member 14, and when the shaping member 17 moves to a position where it protrudes toward the upper shaping device 10 during the movement of the shaping member 14, the shaping member 14 and the shaping member 17 move alternately along the conveyance direction.

[0041] When the fiber sheet 20 enters between the upper shaping device 10 and the lower shaping device 11, the pair of protrusions 17a of the shaping member 17 enters inside the longitudinal peaks 20a of the fiber sheet 20. This maintains the bulk of the longitudinal peaks 20a.

[0042] Furthermore, the longitudinal peaks 20a are pressed in a first direction (e.g., downward) by the protrusions 14a of the shaping member 14 before and after the portions where the bulk of the longitudinal peaks 20a is maintained by the protrusions 17a of the shaping member 17. In this manner, the meshing of the shaping members 14 and 17 causes the fiber sheet 20 to bend so as to present an uneven shape 20e (see FIG. 9) including the widthwise valleys 20c (see FIG. 9) and the remaining portions 20d (see FIG. 9) of the longitudinal peaks 20a.

[0043] At this time, the flexure retaining member 4 fits into the recess 17 b of the shaping member 17 and the recess 14 b of the shaping member 14 , so that the flexure retaining member 4 does not interfere with the shaping member 14 or the shaping member 17 .

[0044] Next, the process proceeds to a step of heating the fiber sheet 20 that has been bent so as to present an uneven shape 20e by partially pressing the longitudinal peaks 20a and / or the longitudinal valleys 20b.

[0045] This process is preferably a process of heating the fiber sheet 20 that has been bent so as to present an uneven shape 20e including widthwise valley portions 20c formed by partially pressing the longitudinal peak portions 20a and the remaining portions 20d of the longitudinal peak portions 20a.

[0046] In this step, in this embodiment, hot air is blown onto the fiber sheet 20. This causes the uneven shape 20e to be formed in the fiber sheet 20. The temperature of the hot air is preferably in the range of 50 to 350 degrees, more preferably 70 to 330 degrees, and even more preferably 80 to 300 degrees. Note that the width of the fiber sheet 20 is approximately the same from the time it passes through the bending forming unit 3 until the uneven shape 20e is formed.

[0047] The means for heating the fiber sheet 20 is not limited to hot air, and other heating means may be used, such as near infrared rays, mid-infrared rays, far infrared rays, conductive heat, steam, ultrasonic waves, superheated steam, high frequency waves, low frequency waves, electromagnetic waves, and atmospheric heating.

[0048] The step of heating the fiber sheet 20 may be performed in any of the steps from bending the fiber sheet 20 so as to wrinkle it in the width direction to bending the fiber sheet 20 so as to form the uneven shape 20e, or may be performed in all of these steps. The heating direction may be any direction, regardless of whether it is up, down, left, or right, relative to the fiber sheet 20. Furthermore, different temperatures may be used for each step, or heating may be performed gradually. Furthermore, the fiber sheet 20 may be cooled to a temperature lower than the heating temperature during or after forming the uneven shape.

[0049] In this embodiment, the bulkiness of the uneven shapes 30c formed on the shaped fiber sheet 30 is uniform, but the bulkiness may be different. Also, the shape, pitch, and arrangement do not necessarily have to be uniform, and different shapes, pitches, and arrangements may be used.

[0050] In this embodiment, the process of partially pressing the longitudinal peaks 20 a in a first direction using the shaping member 14 has been described as an example. However, a process of partially pressing the longitudinal valleys 20 b in a second direction using the shaping member may also be provided. The second direction is, for example, the opposite direction to the first direction, and in this embodiment, it is a downward-to-upward direction. In this case, after this process, a process of heating the bent fiber sheet so as to have an uneven shape including the widthwise peaks formed by partially pressing the longitudinal valleys 20 b and the remaining portions of the longitudinal valleys 20 b may be provided.

[0051] In addition, by using the endless tracks 13a, 16a as in this embodiment, the time (distance) that the shaping members 14, 17 fit into the fiber sheet 20 is increased, which has the advantage of allowing for a longer heating time. This allows for faster shaping of the fiber sheet 20. Furthermore, since the shaping members 14, 17 can be gradually interlocked, high-bulk convex portions can be formed without interference between the shaping members. Furthermore, the height of the convex portions can be varied during the shaping process. Furthermore, the device can be made lighter than when, for example, an embossing roll is used for shaping. If an embossing roll is used, attempting to form high-bulk convex portions, for example, exceeding 10 mm, would require a large embossing roll, making it difficult to further increase the bulk of the convex portions (or deepen the concave portions).

[0052] The speed at which the width-bent fiber sheet is conveyed is preferably equal to or greater than the drive speed of the endless tracks 13a, 16a. This is because, when forming the uneven shape in the fiber sheet, excessive tensile force is not applied to the fiber sheet, making the fiber sheet less likely to stretch and tear. Furthermore, by bending the fiber sheet in the width direction and by using the speed difference between the conveying speed of the fiber sheet in the conveying direction and the drive speed of the endless tracks, the fiber sheet is also bent, thereby ensuring the distance between the peaks and valleys.

[0053] FIG. 10 is a diagram showing a shaped fiber sheet obtained by the shaped fiber sheet manufacturing method of this embodiment.

[0054] As shown in Figure 10, the shaped fiber sheet 30 shaped by the above-mentioned manufacturing method has a shaped uneven shape (in the figure, uneven shape 30c consisting of widthwise valleys 30a and remaining portions 30b of longitudinal peaks) that is repeated continuously along the surface direction. In addition, wrinkles occur between the widthwise valleys 30a and remaining portions 30b of the longitudinal peaks. That is, wrinkles occur on the side portions of the remaining portions 30b. When tension is applied along the surface direction, the uneven shape stretches so that the bulkiness of the uneven shape is reduced partially or entirely, and when the tension is released, the uneven shape has elasticity that contracts so that the uneven shape is restored. When the bulkiness of the uneven shape is reduced partially or entirely, for example, the uneven shape disappears.

[0055] In this embodiment, the shaped fiber sheet 30 is stretchable regardless of the direction of tension applied, as long as it is along the surface direction, regardless of the arrangement direction of the uneven shapes 30c. For example, in the case of filling for clothing or bedding, it is preferable that the sheet has an elongation rate that allows it to recover even if stretched within a range that does not destroy the fabric. Specifically, an elongation rate of 5% to 300% is preferable, an elongation rate of 20% to 300% is more preferable, and an elongation rate of 20% to 200% is even more preferable.

[0056] As an example of measuring elongation, for example, there is a method of cutting the shaped fiber sheet to be measured to 10 cm x 10 cm, and clamping the opposing sides of the vertical and horizontal sides from the edge of the sheet to a distance of 1 cm inward and stretching them within a range that does not break.In addition, for example, there is a method of cutting the shaped fiber sheet to be measured to 10 cm x 10 cm, and clamping the diagonal corners from the corner of the sheet to a width of 1 cm inward and stretching them within a range that does not break.In addition, these are examples of measuring elongation, and any appropriate measurement method can be adopted.

[0057] The fiber sheet 20 is preferably spunbond, thermalbond, air-through, or spunlace. The basis weight is preferably 5 gsm to 200 gsm, more preferably 5 gsm to 150 gsm, and even more preferably 8 gsm to 100 gsm. The area ratio (projected area (projected area after processing) ÷ surface area (raw fabric area before processing)) is preferably 9% to 90%, more preferably 25% to 85%, and even more preferably 35% to 80%.

[0058] The shaped fiber sheet 30 has advantages such as easier definition of the outer shape, bulkiness, and elasticity, and enabling continuous production, compared to the wrinkle processing shown in Patent Document 1. Furthermore, compared to embossing, thin portions (weak portions) are less likely to occur, resulting in excellent resilience, less damage to the function and texture of the raw fabric, and the ability to use functional materials.

[0059] Specifically, embossing compresses and stretches a fiber sheet, which can cause problems such as crushing, hardening, and increased density in the compressed areas. Meanwhile, stretching weakens the material (reducing resilience) and reduces density in the stretched areas. Hollow fibers, for example, can be crushed or destroyed by stretching, resulting in loss of functionality. The same applies to split fibers. Therefore, embossing is not suitable for functional fibers. However, in this embodiment, the fiber sheet is pre-flexed to wrinkle in the width direction, making this problem less likely to occur.

[0060] Furthermore, in this embodiment, the fiber sheet is not (hard to) be compressed or stretched, so wrinkles occur around the convex portions (mainly on the side surfaces). Furthermore, since the wrinkled portions have the effect of reinforcing the support of the convex portions, even if the convex portions are crushed, they have good recovery properties. Furthermore, since embossing involves compression and stretching, if there are minute holes, cuts, frays, etc. in the fiber sheet (raw web) before processing, these will expand and result in a defective product. However, in this embodiment, the fiber sheet is not (hard to) be compressed or stretched, so even if there are minute holes, cuts, frays, etc. in the fiber sheet (raw web) before processing, these will not expand, and production yield will also be improved.

[0061] Due to these characteristics, the shaped fiber sheet 30 of this embodiment is suitable for the following uses.

[0062] For example, it is suitable for use as stuffing (batting). Specifically, it is suitable for use as stuffing for clothing, bedding, outdoor equipment, cushions, and stuffed toys. When used as stuffing, for example, cotton balls, down, feathers, tow, beads, straw, foam beads, pellets, granular cotton, SAP, flakes, activated carbon, and zeolite can be used in the space.

[0063] It is also suitable for use as a heat insulating material, for example, a plastic bottle cover or a packaging material.

[0064] It is also suitable for sound absorbing materials, for example, soundproof sheets (for automobiles, houses, acoustics, etc.).

[0065] The composition is also suitable for cleaning tools, such as flooring sheets, cleaning sheets, and wet tissues.

[0066] It is also suitable for absorbents, such as the surface material of diapers, sanitary products, water supply sheets, and drip sheets.

[0067] The composition is also suitable for use as a dissipative material (diffusing material), for example, as an air freshener, a deodorizer, a disinfectant, an antibacterial agent, an antifungal agent, a humidifier, or a heat dissipating material.

[0068] The material is also suitable for filters (gas and liquid), such as bags, cylinders, laminates, rolls, and composites.

[0069] The material is also suitable for covers, such as stain-proof covers, dust-proof covers, rain-proof covers, waterproof covers, oil-proof covers, sun-protection covers, sunshade covers, insect-proof covers, bird-proof covers, animal-proof covers, and frost-proof covers.

[0070] It is also suitable for agricultural and forestry materials, for example, seedbeds and compost rolls.

[0071] It is also suitable for use as a construction material, for example, as a curing sheet, or as a reinforcing or core material for cement, concrete, mortar, putty, or adhesive.

[0072] The present invention is also suitable for use as a container, for example, a bag or box to be placed in a cell section.

[0073] The shaped fiber sheet 30 may be used alone, in multiple layers, folded, or rolled. It may also be composited or laminated with different fiber sheets. For example, it may be composited or laminated with different materials, such as fabrics, leather, paper, fiber sheets, films (such as breathable films and air-permeable films), sheets, polyolefin cross-laminated fiber nonwoven fabrics, nets, and meshes. Materials include, for example, cotton, hemp, bamboo, kenaf, natural leather, synthetic leather, silk, wool, pulp, rayon, viscose, polyester, polyethylene, polypropylene, styrene, ABS, acrylic, nylon, polycarbonate, vinyl chloride, urethane, synthetic resins, aluminum, silver, gold, platinum, copper, iron, stainless steel, metals, natural rubber, synthetic rubber, elastomers, and silicone, regardless of whether they are natural, synthetic, or semi-synthetic. These materials may also be used alone, composites, blends, or mixed materials. The shaped fiber sheets 30 may also be joined together, or joined to a different fiber sheet, or joined to a film, etc. In this case, the joining method may include, but is not limited to, adhesion, heat welding, ultrasonic welding, high-frequency welding, low-frequency welding, crimping, sewing, etc.

[0074] When the shaped fiber sheet is used as padding for clothing, bedding, sleeping bags, etc., it is preferable that the width of the convex portion of the shaped fiber sheet is larger than the width of the concave portion. This allows the shaped fiber sheets to be stacked facing each other without interlocking, thereby maintaining bulk.

[0075] In the above embodiment, the shaping member 17 maintains the bulkiness while the shaping member 14 partially presses the longitudinal peaks 20a of the fiber sheet 20 along the width direction, but the longitudinal peaks 20a may be partially pressed along the width direction by other methods. Figure 11 is an explanatory diagram showing a modified example of the method for manufacturing a shaped fiber sheet.

[0076] For example, as shown in Fig. 11(a), a fiber sheet 20 that has been bent so as to wrinkle in the width direction in the same manner as in the above-described manufacturing method is passed over a plate 40 having elongated holes 40a extending in the width direction. Then, as shown in Fig. 11(b), as the fiber sheet 20 passes over the elongated holes 40a, protruding piece-shaped shaping members 41 are inserted into the elongated holes 40a. This allows the longitudinal peaks 20a of the fiber sheet 20 to be partially pressed along the width direction, as shown in Fig. 11(c).

[0077] In the above embodiment, an example was given in which the endless tracks 13a, 16a were made straight, but as shown in Figure 12, when transporting a fiber sheet 20 between an upper endless track 50 and a lower endless track 51, the endless tracks 50, 51 may be given a gentle slope at the entrance portion 52 and the exit portion 53 through which the fiber sheet 20 is transported.

[0078] This allows the shaping members 50a provided on the endless track 50 and the shaping members 51a provided on the endless track 51 to gradually mesh together, so that the flexure of the fiber sheet 20 can be deepened and an uneven shape can be formed in the fiber sheet 20 without providing a flexure retention member 4. In addition, the fiber sheet 20 can be transported smoothly.

[0079] In the above embodiment, an example was given in which the fiber sheet 20 is bent so as to wrinkle in the width direction by passing through the gap between the roller 7 of the upper roller group 8 and the roller 7 of the lower roller group 9, but the method of bending the fiber sheet 20 so as to wrinkle in the width direction does not have to be limited to the method shown in the above embodiment.

[0080] For example, as shown in Fig. 13(a), the fiber sheet 20 can be bent by sandwiching it between corrugated rollers 90 arranged above and below. Specifically, the rollers 90 include rollers 90a whose tip is convex toward the fiber sheet 20 and rollers 90b whose tip is concave toward the fiber sheet 20. The rollers 90a and 90b are alternately arranged in the width direction and are arranged to face each other across the fiber sheet 20. The rollers 90a and 90b are supported by a pair of shafts 15 that extend in the width direction and are arranged above and below, and the fiber sheet 20 is sandwiched between the rollers 90a and 90b from above and below the fiber sheet 20.

[0081] 13(b), the fiber sheet 20 can be bent by sandwiching it between rollers 91 of different diameters arranged above and below. Specifically, rollers 91 are provided as rollers 91, one with a small diameter and the other with a large diameter. The rollers 91a and 91b are arranged alternately in the width direction and are arranged so as to face each other across the fiber sheet 20. The rollers 91a and 91b are supported by a pair of shafts 15 extending in the width direction and arranged above and below, and the fiber sheet 20 is sandwiched between the rollers 91a and 91b from above and below the fiber sheet 20.

[0082] 13(c), the fiber sheet 20 can be bent by sandwiching it between uneven rollers 92. Specifically, a pair of shafts 15a and 15b having different vertical heights are provided above the fiber sheet 20. Shaft 15b is located higher than shaft 15a. A pair of shafts 15c and 15d having different vertical heights are also provided below the fiber sheet 20. Shaft 15c is located higher than shaft 15d. Rollers 92a, 92b, 92c, and 92d having the same shape and size are provided as rollers 92.

[0083] By supporting roller 92a on shaft 15a and roller 92b on shaft 15b, rollers 92a and 92b are vertically staggered. By supporting roller 92c on shaft 15c and roller 92d on shaft 15d, rollers 92c and 92d are vertically staggered. By arranging rollers 92a and 92d so that they face each other across the fiber sheet 20, and rollers 92b and 92c face each other across the fiber sheet 20, rollers supported on shafts distant from the fiber sheet 20 do not face each other, thereby reducing the gap between the rollers. The fiber sheet 20 is sandwiched between rollers 92a and 92b and rollers 92c and 92d from above and below the fiber sheet 20.

[0084] 13(d), for example, the fiber sheet 20 can be bent by sandwiching the fiber sheet 20 between corrugated wires 93 arranged above and below. Specifically, a plurality of wires 93 are arranged in the conveying direction, and the fiber sheet 20 is sandwiched between the wires 93 from above and below the fiber sheet 20.

[0085] 14(a), for example, upper and lower folding plates 60, 61 may be disposed upstream of the shaping unit 5. Then, as shown in FIG. 14(b), by conveying the fiber sheet 20 so as to pass through the gap between the upper and lower folding plates 60, 61, the upper folding plate 60 may form longitudinal valleys 20b and the lower folding plate 61 may form longitudinal peaks 20a, thereby bending the fiber sheet 20 so as to wrinkle it in the width direction.

[0086] In addition, the method of bending the fiber sheet 20 is not limited to the above embodiment, and may be, for example, by pressing a protrusion against the fiber sheet 20, bending it with a corrugated suction box, bending it with partial vacuum, or bending it with strong and weak vacuum.

[0087] In the above embodiment, an example was given in which the bulk of the fiber sheet 20 is not changed in the process of partially pressing the longitudinal peaks 20a and longitudinal valleys 20b of the fiber sheet 20 that has been bent so as to wrinkle in the width direction, but the bulk of the fiber sheet 20 may also be adjusted.

[0088] 15, for example, by disposing rollers 13b, 16b that change the tracks of the endless tracks 13a, 16a, it is possible to adjust the bulk of the fiber sheet 20 so that it is higher. Note that the bulk of the fiber sheet 20 may also be adjusted so that it is lower.

[0089] In this way, by providing low and high bulkiness portions of the uneven shape of the shaped fiber sheet, when the shaped fiber sheet is folded or stacked so that the front and back surfaces face each other, interference between the convex portions can be reduced. Also, when used as padding for clothing, for example, the convex portions can be prevented from being noticeable from the surface.

[0090] In the above embodiment, an example was given in which the uneven shapes of the shaped fiber sheet are arranged in the same row along the conveying direction, but the positions of the uneven shapes of the shaped fiber sheet in the width direction may also be shifted so that they are staggered.

[0091] For example, the relative positions of the shaping members 14 are shifted in the width direction to shift the positions of the protrusions 14a in the width direction, and the relative positions of the shaping members 17 in each pair are shifted in the width direction to shift the positions of the protrusions 17a in the width direction. By interlocking the shaping members 14 and 17 in this arrangement, the positions of the concave and convex shapes of the shaped fiber sheet can be shifted in the width direction.

[0092] In the above embodiment, the fiber sheet 20 is bent so as to have an uneven shape by the protrusions 14a of the shaping member 14 and the protrusions 17a of the shaping member 17, but the shape of the shaping member may be different from that in the above embodiment.

[0093] For example, as shown in Fig. 16(a), the fiber sheet 20 may be bent to have an uneven shape by a shaping member 70 whose tip is bent in the opposite direction to the conveying direction of the fiber sheet 20. Note that the tip of the shaping member 70 is formed in an arc shape to prevent the fiber sheet 20 from getting caught, but as a modified example of the shaping member 70, not only the tip but also the bent end may be formed in a substantially circular shape, as in the shaping member 71 shown in Fig. 16(b).

[0094] 17(a), the fiber sheet 20 may be bent to have an uneven shape by a cylindrical shaping member 72. In the example of FIG. 17(a), the shaping members 72 are arranged linearly along the width direction perpendicular to the conveying direction of the fiber sheet 20, but as shown in FIG. 17(b), the shaping members 72 may be arranged along the width direction so that their positions along the conveying direction are staggered. Furthermore, although not shown, irregularly shaped shaping members may be arranged.

[0095] As a modification of the shaping member 72, a shaping member 73 with a pan-head-shaped tip may be used, as shown in FIG. 18(a). A shaping member 74 with a chamfered tip may be used, as shown in FIG. 18(b). A cylindrical shaping member 75 may be used, as shown in FIG. 18(c). A rectangular tubular shaping member 76 may be used, as shown in FIG. 18(d). In the examples of FIGS. 18(c) and 18(d), there is a portion of the top surface that is not pressed, so that the texture and function of the raw roll are not impaired. A polygonal prism-shaped shaping member 77 may be used, as shown in FIG. 18(e). A cross-prism-shaped shaping member 78 may be used, as shown in FIG. 18(f). A protruding piece-shaped shaping member 79 elongated in the conveying direction may be used, as shown in FIG. 18(g). Other shaping members, such as star-shaped shaping members, may also be used, and the shape of the shaping member is not limited to the shape exemplified in this embodiment.

[0096] Furthermore, for example, as shown in Fig. 19(a), a shaping member 80 having a curved, chamfered tip may be used to bend the fiber sheet 20 to create an uneven shape. By making the tip curved in this manner, the fiber sheet 20 can be conveyed smoothly. As a modification of the shaping member 80, a shaping member 81 having a truss-head-shaped tip may be used as shown in Fig. 19(b). Alternatively, a shaping member 82 having a spherical tip may be used as shown in Fig. 19(c).

[0097] For example, as shown in FIG. 20( a), the fiber sheet 20 may be bent to have an uneven shape by a corrugated shaping member 83 having curved wall surfaces that are continuous in the width direction. As a modified example of the shaping member 83, as shown in FIG. 20( b), a corrugated shaping member 84 having semicircular wall surfaces that are continuous in the width direction may be used. As shown in FIG. 20( c), a corrugated shaping member 85 having arc-shaped wall surfaces that are bent to a semicircle or more that are continuous in the width direction may be used. As shown in FIG. 20( d), a corrugated shaping member 86 having V-shaped wall surfaces that are continuous in the width direction may be used. Other examples include an intermittent corrugated shape and a rectangular wave shape.

[0098] Next, a specific description will be given of the case where the shaped fiber sheet 30 manufactured by the manufacturing method of the present invention is used as filling for textile products such as clothing and bedding.

[0099] Conventionally, when down or short-fiber granules are used as filling for products such as futons and clothing, fiber shedding and unevenness occur due to blowing out from the outer fabric. Therefore, in order to prevent fiber shedding, limitations are imposed on the outer fabric, such as the need to use high-density woven fabrics or to apply calendaring. Furthermore, to prevent fiber unevenness, processing such as quilting or stitching is required for the outer fabric. However, since the shaped fiber sheet 30 is manufactured by laminating long-fiber fiber sheets 20, fiber shedding and unevenness due to blowing out are almost nonexistent. This prevents dust generation due to blowing out and makes washing easier.

[0100] Furthermore, because the shaped fiber sheet 30 hardly loses fibers due to blowing, the flexibility of the fabric used as the outer fabric can be increased. For example, open-weave fabrics that could not be used in the past can be used as the outer fabric. Specifically, low-density fabrics such as gauze and waffle, knits, and stretch woven fabrics can be used as the outer fabric. In addition, polyolefin cross-laminated nonwoven fabrics can be used as part of the laminate that makes up the outer fabric.

[0101] Furthermore, since the shaped fiber sheet 30 has almost no bias, there is no need for quilting or stitching on the outer fabric. This prevents heat from escaping to the outside through quilting, stitching, or other processing. Furthermore, the outer fabric presses down on the batting less, allowing for a larger air layer to be maintained. As a result, the product can be made lighter than when using conventional batting, and its heat retention can be improved. Furthermore, processing such as quilting or stitching on the outer fabric can be omitted.

[0102] Furthermore, there is no need to use a high-density outer fabric with low conformability to the body as the outer fabric, and furthermore, since processing such as quilting or stitching is not required for the outer fabric, a low-density outer fabric with high conformability to the body can be used. In other words, instead of using a thick, hard outer fabric as in the past, a soft outer fabric with less thickness compared to conventional fabrics can be used. This improves the product's conformability to the body. Therefore, when the shaped fiber sheet 30 is used as padding for clothing, comfort can be improved. It can also improve design.

[0103] Furthermore, the shaped fiber sheet 30 has a low density, which allows moisture to escape. Furthermore, by laminating a rayon nonwoven fabric, moisture absorption and heat generation can be easily achieved.

[0104] Here, for example, ten layers of the shaped fiber sheet 30 can be used as the filling of a comforter. As an example, a comforter using the shaped fiber sheet 30 as the filling weighs approximately 1.9 kg (26 g / m) in a single size (width 1500 mm x length 2100 mm, thickness approximately 50 mm). ２In comparison, for the same size comforters using conventional filling, the down comforter weighed around 2.5 kg, the silk comforter around 2.3 kg, the feather comforter around 3 kg, the wool comforter around 3.5 kg, the polyester comforter around 2 kg, and the cotton comforter around 4.5 kg. In this way, comforters using the shaped fiber sheet 30 as filling are lighter than comforters using conventional filling.

[0105] In addition, the heat retention of the shaped fiber sheet 30 manufactured by the manufacturing method of the present invention was tested using Method A (constant temperature method) of the test method (JIS L 1096) specified in JIS (Japanese Industrial Standards). The test involved placing a sample (40 cm x 40 cm) cushion on a constant temperature hot plate, and determining the heat retention rate (%) from the amount of heat dissipation (proportional to power consumption) when the surface temperature of the constant temperature hot plate was maintained at a constant value (36 ° C ± 0.5 ° C). The values ​​in parentheses indicate the CLO value. The results are from two measurements of one test piece.

[0106] As a result, the heat retention rate of the shaped fiber sheet 30 (14g) was 80.1% (3.07), the heat retention rate of the granular cotton 3D (14g) was 73.0% (2.06), the heat retention rate of the granular cotton 7D (14g) was 73.7% (2.13), the heat retention rate of the down (14g) was 84.0% (4.01), the heat retention rate of the Fine Polygon (registered trademark) (14g) was 78.0% (2.69), and the heat retention rate of the shaped fiber sheet 30 (21g) was 84.1% (4.02).

[0107] In this way, the shaped fiber sheet 30 can take in air into the space formed by the uneven shape 20e to form an air layer, so a comforter using the shaped fiber sheet 30 as the filling can achieve better heat retention than a comforter using conventional filling.

[0108] As shown in Figure 22, for example, when the shaped fiber sheet 30 of the present invention is used as the filling of a comforter as an example of a textile product, there are fewer gaps than with filling using conventional heat-insulating material, thereby improving heat retention.

[0109] Examples of textile products include bedding such as futons and sleeping bags, general clothing, sportswear, clothing materials, interior products such as carpets, sofas, curtains, and cushions, vehicle interior products such as car seats, household uses such as cosmetics, cosmetic masks, wiping cloths, and health products, and environmental and industrial material uses such as filters and products for removing harmful substances.

[0110] The present invention has been described above by showing preferred embodiments, but it goes without saying that the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention.

[0111] For example, in the process of bending the fiber sheet so as to wrinkle it in the width direction, the fiber sheet may be bent by a method different from that of the above embodiment, such as by moving the fiber sheet toward the center in the width direction or by bending the fiber sheet in the thickness direction. Furthermore, the shape of the bend is not limited to that of the present embodiment, and may be a shape different from that of the above embodiment.

[0112] Furthermore, the process of bending the fiber sheet so as to wrinkle it in the width direction does not have to be limited to bending it in a zigzag shape, and the fiber sheet may be bent in a manner different from the above embodiment, for example, so that a single longitudinal peak or valley extending along the conveying direction is formed in the fiber sheet.

[0113] In addition, in the process of heating the fiber sheet 20 that has been bent to present the uneven shape 20e by partially pressing the longitudinal peaks 20a and / or longitudinal valleys 20b, an example was described in which hot air was blown onto the fiber sheet 20 from both sides to form the uneven shape 20e. However, in the process of heating the fiber sheet 20, the fiber sheet 20 may be heated by blowing hot air onto the fiber sheet 20 from one side, the hot air blown onto the fiber sheet 20 may be sucked onto the other side of the fiber sheet 20, and the sucked hot air may be blown onto the fiber sheet 20 again from one side. In this way, by blowing the sucked hot air again onto the fiber sheet 20, heat loss can be suppressed. Furthermore, since the fiber sheet 20 is pressed against the shaping members 14 and 17 by suction, the uneven shape 20e can be easily formed on the fiber sheet 20.

[0114] REFERENCE SIGNS LIST 1 shaped fiber sheet manufacturing device 2 conveying path 3 deflection forming section 4 deflection holding member 5 shaping section 10 upper shaping device 11 lower shaping device 20 fiber sheet 20a longitudinal peak portion 20b longitudinal valley portion 30 shaped fiber sheet

Claims

1. a step of conveying a long fiber sheet and bending the fiber sheet in a width direction so as to wrinkle the fiber sheet in a width direction to include longitudinal peaks and / or longitudinal valleys extending in a longitudinal direction along a conveying direction; The fiber sheet bent so as to be wrinkled in the width direction is conveyed between endless tracks driven along the conveying direction on both sides of the thickness direction of the fiber sheet, thereby partially pressing the longitudinal peaks and / or the longitudinal valleys by meshing with shaping members arranged in a row on the endless tracks along the conveying direction; and heating the fiber sheet bent so as to have an uneven shape by partially pressing the longitudinal peaks and / or the longitudinal valleys, In the step of bending the fiber sheet so as to wrinkle it in the width direction, the fiber sheet is wrinkled in the width direction while being conveyed so that the longitudinal peaks and the longitudinal valleys are alternately arranged along the width direction perpendicular to the conveying direction, In the step of partially pressing the longitudinal peaks and / or longitudinal valleys of the fiber sheet bent so as to wrinkle in the width direction, the fiber sheet is conveyed so as to pass through gaps between folding plates arranged above and below, whereby the longitudinal valleys are formed by the upper folding plate and the longitudinal peaks are formed by the lower folding plate, thereby bending the fiber sheet so as to wrinkle in the width direction. A method for producing a shaped fiber sheet comprising the steps of:

2. A method for producing a shaped fiber sheet as described in claim 1, characterized in that in the process of partially pressing the longitudinal peaks and / or the longitudinal valleys of the fiber sheet that has been bent so as to wrinkle in the width direction, it is possible to adjust the bulk of the longitudinal peaks and / or the longitudinal valleys.

3. A method for manufacturing a shaped fiber sheet as described in claim 1, characterized in that in the process of bending the fiber sheet so as to wrinkle it in the width direction, the fiber sheet is transported so as to pass through a gap between rollers arranged above and below, thereby forming the longitudinal valley portion with the upper roller and forming the longitudinal peak portion with the lower roller, thereby bending the fiber sheet so as to wrinkle it in the width direction.

4. A process for conveying a long fiber sheet and bending the fiber sheet in a width direction so as to wrinkle the fiber sheet in such a way that the fiber sheet includes longitudinal peaks and / or longitudinal valleys extending longitudinally along the conveying direction; The fiber sheet bent so as to be wrinkled in the width direction is conveyed between endless tracks driven along the conveying direction on both sides of the thickness direction of the fiber sheet, thereby partially pressing the longitudinal peaks and / or the longitudinal valleys by meshing with shaping members arranged in a row on the endless tracks along the conveying direction; A textile product characterized in that a shaped fiber sheet produced by a shaped fiber sheet producing method including a step of heating the fiber sheet that has been bent so as to have an uneven shape by partially pressing the longitudinal peaks and / or the longitudinal valleys is used as a filling.