Web member production device and web member production method

Abstract

Provided is a web member production device (10) comprising an upstream-side conveyance mechanism (20) that conveys a continuous web member (1a) including tows which are continuous in the conveyance direction, a cutting mechanism (30) that cuts the continuous web member (1a) conveyed by the upstream-side conveyance mechanism (20), and a downstream-side conveyance mechanism (40) that conveys, in the conveyance direction, web members (1) into which the cutting mechanism (30) has cut the web member (1a) at production pitches (P1), wherein: the cutting mechanism (30) includes a first roller (31b) and a second roller (31a) that have respective outer circumferential surfaces facing each other; at least the first roller (31b) includes a cutting blade (31bs); as viewed in the radial direction of the first roller (31b), the longitudinal direction of the cutting blade (31bs) is inclined with respect to the rotation center axis (C31b) of the first roller (31b); and the cutting mechanism (30) cuts the continuous web member (1a) while conveying the continuous web member (1a) in the conveyance direction and while causing the conveyance surface of the downstream-side conveyance mechanism (40) and the continuous web member (1a) to slide relative to each other.

Description

Web member manufacturing apparatus and web member manufacturing method

[0001] The present invention relates to an apparatus for manufacturing a web member and a method for manufacturing a web member.

[0002] Conventionally, as in Patent Document 1, there is known a cleaning tool in which a gripping tool is inserted into a cleaning member to enable it to be used for cleaning a tabletop or the like. This cleaning member is made of a fiber bundle of thermoplastic fiber called tow. In a production line for this cleaning member, a base sheet is formed in a conveyance direction, and fiber bundles, the fiber direction of which is aligned with the conveyance direction, are fixed to the base sheet. This forms a laminated web that is continuous in the conveyance direction as a semi-finished product. Finally, the continuous laminated web is cut at a product pitch to form single-sheet cleaning members.

[0003] JP 2014-129633 A

[0004] One method for cutting a continuous laminated web at a product pitch is to pass the continuous laminated web between a cutter roll having a cutter blade on its outer circumferential surface and an anvil roll having a receiving blade that receives the cutter blade. While conveying the continuous laminated web, the web material is clamped between the cutter blade and the receiving blade, thereby cutting the web material. However, because the tows of the fiber bundles are thermoplastic fibers, the pressure between the cutter blade of the cutter roll and the receiving blade of the anvil roll tends to cause the fiber bundles (tows) at the cutting position to stick together. As a result, the cut edges may become sealed or clumps may form, which may impair the ability of the cleaning member to trap dust when used as a cleaning tool.

[0005] The present invention has been made in consideration of the above-mentioned problems, and its object is to provide a web member manufacturing apparatus and a web member manufacturing method that can improve the manufacturing efficiency of web members while reducing the risk of tow fibers sticking together at the cut surface.

[0006] The primary invention for achieving the above object is a web member manufacturing apparatus including an upstream conveying mechanism that conveys a continuous web member including a continuous tow in a conveying direction, a cutting mechanism that cuts the continuous web member conveyed by the upstream conveying mechanism, and a downstream conveying mechanism that conveys the web member cut into product pitches by the cutting mechanism in the conveying direction, wherein the cutting mechanism includes a first roll and a second roll whose outer peripheral surfaces face each other, at least the first roll is equipped with a cutting blade, the longitudinal direction of the cutting blade being inclined with respect to the central axis of rotation of the first roll as viewed in the radial direction of the first roll, and the cutting mechanism cuts the continuous web member while conveying the continuous web member in the conveying direction and while sliding the conveying surface of the downstream conveying mechanism relative to the continuous web member. Other features of the present invention will become apparent from the description of this specification and the accompanying drawings.

[0007] According to the present invention, it is possible to improve the manufacturing efficiency of the web member while reducing the risk of the fibers of the tow sticking together at the cut surface.

[0008] FIG. 2A is a perspective view of the web member 1. FIG. 2B is a cross-sectional view taken along line A-A in FIG. 2A. FIG. 4A is a schematic side view of the manufacturing apparatus 10 of this embodiment. FIG. 4B is a view taken along line B-B in FIG. 4A. FIG. 4B is a view taken along line C-C in FIG. 4A. FIG. 4A is a schematic diagram illustrating the upper cutting blade 31as and the lower cutting blade 31bs of the cutting mechanism 30. FIG. 7A is an enlarged view of portion X in FIG. 4B. FIG. 7B is a diagram illustrating the cutting process of the semi-finished product 1a in the state of FIG. 7A. FIG. 6 is a diagram illustrating the semi-finished product 1a in the state (d) in FIG. 6. FIG. 4B is a schematic diagram illustrating a modified example of the cutting mechanism 30.

[0009] At least the following points become clear from the description in this specification and the accompanying drawings: (Aspect 1) A web member manufacturing apparatus having an upstream conveying mechanism that conveys a continuous web member including a tow that is continuous in a conveying direction, a cutting mechanism that cuts the continuous web member conveyed by the upstream conveying mechanism, and a downstream conveying mechanism that conveys the web member cut into product pitches by the cutting mechanism in the conveying direction, wherein the cutting mechanism comprises a first roll and a second roll whose outer circumferential surfaces face each other, at least the first roll is equipped with a cutting blade, the longitudinal direction of the cutting blade being inclined with respect to the central axis of rotation of the first roll as viewed in the radial direction of the first roll, and the cutting mechanism cuts the continuous web member while conveying the continuous web member in the conveying direction and while sliding the continuous web member against the conveying surface of the downstream conveying mechanism relative to one another.

[0010] According to the first aspect, it is possible to improve the manufacturing efficiency of the web member while reducing the risk of the fibers of the tow sticking together at the cut surface.

[0011] (Aspect 2) A manufacturing apparatus for a web member according to Aspect 1, characterized in that the downstream conveying speed at which the web member is conveyed in the downstream conveying mechanism is faster than the cutting conveying speed at which the continuous web member is conveyed in the cutting mechanism.

[0012] According to aspect 2, the risk of the web member remaining stuck in the cutting mechanism after cutting is reduced, and the continuous web member can be cut while being pulled in the conveying direction, making it easier to cut the continuous web member and reducing the risk of the tow fibers at the cut surface sticking together.

[0013] (Aspect 3) In the apparatus for manufacturing a web member according to Aspect 1, the cutting and conveying speed is faster than an upstream conveying speed at which the continuous web member is conveyed in the upstream conveying mechanism.

[0014] According to aspect 3, the risk of the web member remaining stuck in the cutting mechanism after cutting is reduced, and the continuous web member can be cut while being pulled in the conveying direction, making it easier to cut the continuous web member and reducing the risk of the fibers of the tow at the cut surface sticking together.

[0015] (Aspect 4) The apparatus for manufacturing a web member according to Aspect 1, wherein the difference between the downstream conveying speed and the cutting conveying speed is smaller than the difference between the cutting conveying speed and the upstream conveying speed.

[0016] If the downstream conveying speed is too fast, there is a risk that the continuous web member or web member will meander or the web will lift up. According to aspect 4, by making the difference between the downstream conveying speed and the cutting conveying speed smaller than the difference between the cutting conveying speed and the upstream conveying speed, it is possible to reduce the risk that the continuous web member or web member will meander or the web will lift up compared to when the difference between the downstream conveying speed and the cutting conveying speed is larger than the difference between the cutting conveying speed and the upstream conveying speed.

[0017] (Aspect 5) In the apparatus for manufacturing a web member according to aspect 1, the downstream transport mechanism includes a sensor for detecting the transport interval of the web member.

[0018] When poor cutting occurs in the cutting mechanism, the transport intervals of the web material in the downstream transport mechanism tend to become uneven. According to Aspect 5, it is easy to determine whether the web material is properly cut based on the transport intervals of the web material in the downstream transport mechanism.

[0019] (Aspect 6) The apparatus for manufacturing a web member according to Aspect 1, wherein the downstream transport mechanism transports the web member while supporting only the lower side of the web member.

[0020] According to the sixth aspect, the web member is more likely to be opened by air resistance during transport, and the web member is more likely to be kept in a fluffy, soft state.

[0021] (Aspect 7) The web member manufacturing apparatus according to Aspect 1, further comprising an air blowing device that blows air toward the web member supported by the downstream transport mechanism.

[0022] According to aspect 7, it is possible to prevent the web member from floating up while being transported by the downstream transport mechanism, and to reduce the risk of excessive opening of only the transport side surface of the web member.

[0023] (Aspect 8) In the apparatus for manufacturing a web member according to Aspect 1, the downstream transport mechanism does not include a suction mechanism on the transport surface.

[0024] According to aspect 8, since the tow contained in the web member is soft, by not providing a suction mechanism in the downstream conveying mechanism, it is possible to reduce the risk of the tow being sucked in or tangled by the suction mechanism.

[0025] (Aspect 9) The upstream conveying mechanism is a web member manufacturing apparatus according to Aspect 1, characterized in that it comprises an upper conveying section and a lower conveying section, and conveys the continuous web member while sandwiched between the upper conveying section and the lower conveying section.

[0026] According to the ninth aspect, by reducing the thickness of the continuous work member, it becomes easier for the cutting mechanism to cut the continuous web member.

[0027] (Aspect 10) In the apparatus for manufacturing a web member according to Aspect 1, the rotational center axis of the first roll is inclined with respect to a direction perpendicular to the conveying direction.

[0028] According to aspect 10, even if the longitudinal direction of the cutting blade of the first roll is inclined relative to the central axis of rotation of the first roll when viewed in the radial direction of the first roll, it is easy to cut the web member in the desired shape and at the desired position.

[0029] (Aspect 11) The web member manufacturing apparatus according to Aspect 1, wherein the cutting mechanism cuts the continuous web member while the cutting blade, the circumferential surface of the first roll, and the circumferential surface of the second roll are in contact with the continuous web member.

[0030] According to aspect 11, even if the continuous web member is made of a soft material that spreads easily, the peripheral surfaces of the first roll and the second roll press down on the continuous web member prior to cutting in the cutting mechanism, which makes it easier to maintain a constant conveyance amount of the continuous web member in the conveying mechanism and makes it easier to cut the continuous web member.

[0031] (Aspect 12) The web member manufacturing apparatus according to Aspect 1, wherein the thickness of the continuous web member at the time when the continuous web member and the first roll come into contact is less than half the thickness of the web member in the downstream conveying mechanism.

[0032] According to aspect 12, even if the continuous web member is made of a soft, spreadable material, it is easier to cut the continuous web member in the cutting mechanism than when the thickness of the continuous web member at the time when the continuous web member contacts the first roll is greater than half the thickness of the web member in the downstream conveying mechanism.

[0033] (Aspect 13) A method for manufacturing a web member includes an upstream conveying step in which an upstream conveying mechanism conveys a continuous web member including a tow that is continuous in a conveying direction; a cutting step in which a cutting mechanism cuts the continuous web member conveyed by the upstream conveying mechanism; and a downstream conveying step in which a downstream conveying mechanism conveys the web member cut into product pitches by the cutting mechanism in the conveying direction, wherein the cutting mechanism includes a first roll and a second roll whose outer peripheral surfaces face each other, at least the first roll includes a cutting blade, and the longitudinal direction of the cutting blade is inclined with respect to the central axis of rotation of the first roll as viewed in the radial direction of the first roll, and the cutting mechanism cuts the continuous web member while conveying the continuous web member in the conveying direction, and cuts the continuous web member while sliding the conveying surface of the downstream conveying mechanism relative to the continuous web member.

[0034] According to Aspect 13, it is possible to improve the manufacturing efficiency of the web member while reducing the risk of the fibers of the tow sticking together at the cut surface.

[0035] ===Present Embodiment=== <<<Basic Configuration of Web Member 1>>> Fig. 1 is a perspective view of the web member 1. Fig. 2A is a plan view of the web member 1. Fig. 2B is a cross-sectional view taken along line AA in Fig. 2A.

[0036] The planar shape of this web member 1 is a substantially rectangular shape having a longitudinal direction and a width direction, as shown in Figures 1 and 2A. Furthermore, as shown in Figures 1 and 2B, in the thickness direction, a base sheet 2, an auxiliary sheet 3 covering the upper surface of the base sheet 2, a fiber bundle member 5G covering the lower surface of the base sheet 2 and forming a main brush section, and a strip sheet 7 provided on the lower surface of the fiber bundle member 5G and forming an auxiliary brush section are provided. Hollow portions SP3, SP3 into which a handle member 9 is inserted and fixed are defined between the auxiliary sheet 3 and the base sheet 2. The bifurcated insertion portions 9a, 9a of the handle member 9 are inserted into these hollow portions SP3, SP3, and the underside and both widthwise ends of the web member 1 are used as wiping surfaces for cleaning a tabletop, etc.

[0037] As shown in FIG. 2B , the fiber bundle member 5G is a member in which multiple fiber bundles 5, 5... are stacked in the thickness direction. In this example, a four-layer structure is formed by stacking four fiber bundles 5, 5... as an example of multiple bundles in the thickness direction, but the number of fiber bundles 5, 5... is not limited to this. Each fiber bundle 5 has a tow having a fineness of, for example, 3.5 dtex (diameter 18 to 25 μm) as a large number of long fibers. However, the tow fineness is not limited to 3.5 dtex and may be any value selected from the range of 1.1 to 10 dtex (diameter approximately 6 to approximately 60 μm), for example. Furthermore, each fiber bundle 5 may have tows of multiple finenesses in the range of 1.1 to 10 dtex.

[0038] Each tow is aligned along the width direction of the web member 1. That is, the fiber direction of each tow (the longitudinal direction of the tow) is aligned along the width direction of the web member 1. As a result, both ends in the width direction usually become the tip of the brush part. However, because these tows are flexibly bendable and deformable, when the tip of the tow is bent toward the underside of the web member 1, the underside can also become the tip of the brush part. In this embodiment, all the fibers in each fiber bundle 5 are composed of tow, but this is not limited to this, and the fiber bundle 5 may contain fibers other than tow.

[0039] As described in JIS L 0204-3 1998, section 3.1.24, a "tow" is a fiber bundle (fiber bundle 5) containing a large number of continuous filaments. Examples of fiber bundles include fiber bundles made of thermoplastic fibers and fiber bundles containing thermoplastic fibers. Examples of raw materials for the fibers constituting the fiber bundles include PE (polyethylene), PP (polypropylene), PET (polyethylene terephthalate), nylon, and rayon. These fibers may be, for example, single fibers made of a single component or composite fibers. Examples of composite fibers include composite fibers with a sheath-core structure such as PE / PET or PE / PP, or side-by-side composite fibers such as PE / PET or PE / PP. The fiber bundle may also be a bundle of slit fibers (fibers made by cutting a film into long, thin strips and stretching them), split fibers (fibers made by dividing a long, thin film into a mesh structure), or the like.

[0040] The fineness of the fibers constituting the fiber bundle is preferably 1 to 50 dtex, and more preferably 2 to 10 dtex. The fiber bundle may contain multiple types of fibers having the same fineness, or may contain the same or different types of fibers having different finenesses. The cross-sectional shape of the fibers may be circular or may have other shapes. The fibers may also have crimps. In this case, the fibers are crimped during filament production, and the number of crimps is increased by preheating calendering or hot air treatment.

[0041] The tow in this embodiment is opened at a predetermined stage upstream of a cutting mechanism 30 (described later) in the manufacturing process of the web member 1. The tow is opened by repeatedly applying and releasing tension in the longitudinal direction to the filaments using a well-known method (such as a tension roll) while the tow is being transported by a transport roll, thereby separating the continuous filaments of the tow into individual fibers. The opening of the tow makes the fiber bundle 5 soft and fluffy.

[0042] 1, 2A, and 2B, the base sheet 2 and the auxiliary sheet 3 are both sheets having a substantially rectangular planar shape. They are set to have the same widthwise dimension, but the base sheet 2 is set to be longer in the longitudinal direction. As a result, the auxiliary sheet 3 is laminated on the base sheet 2 with both longitudinal end portions 2e, 2e of the base sheet 2 protruding outward by a predetermined length from both longitudinal end portions 3e, 3e of the auxiliary sheet 3.

[0043] In this embodiment, zigzag cuts k, k... are formed along the width direction at intervals in the longitudinal direction at each end in the width direction of both the base sheet 2 and the auxiliary sheet 3. These cuts k, k... form a plurality of zigzag strips along the width direction at each end in the width direction of the base sheet 2 and the auxiliary sheet 3. However, these cuts k, k... may be absent, and any shape other than zigzag may be used.

[0044] The base sheet 2 and the auxiliary sheet 3 are formed, for example, from a nonwoven fabric containing thermoplastic fibers. Examples of thermoplastic fibers include PE, PP, and PET fibers, composite fibers of PE and PET (e.g., composite fibers with a core-sheath structure in which the core is PE and the sheath is PET), and composite fibers of PE and PP (e.g., composite fibers with a core-sheath structure in which the core is PET and the sheath is PE). Examples of nonwoven fabrics include thermal-bonded nonwoven fabrics, spun-bonded nonwoven fabrics, and spunlaced nonwoven fabrics. However, the materials for the base sheet 2 and the auxiliary sheet 3 are not limited to nonwoven fabrics.

[0045] The strip sheet 7 is formed from a flexible sheet such as a nonwoven fabric containing thermoplastic fibers or a thermoplastic resin film, and is formed into a substantially rectangular shape with approximately the same planar size as the base sheet 2. At each end of the width direction of the strip sheet 7, zigzag cuts (not shown) are formed along the width direction at intervals in the longitudinal direction, and these cuts form a plurality of zigzag strips (not shown) along the width direction at each end of the width direction of the strip sheet 7. However, the strip sheet 7 is not necessary.

[0046] The auxiliary sheet 3, the base sheet 2, the four fiber bundles 5, 5, 5, 5 of the fiber bundle member 5G, and the strip sheet 7 are stacked in this order in the thickness direction and joined together by forming a plurality of welded joints J1, J2, J2... as shown in Figures 2A and 2B. For example, a first welded joint J1 is formed in a straight line along the longitudinal direction at the center position in the width direction, and this first welded joint J1 welds and joins all layers of the web member 1 in the thickness direction (i.e., the entire configuration of the auxiliary sheet 3, the base sheet 2, the four fiber bundles 5, 5... of the fiber bundle member 5G, and the strip sheet 7).

[0047] Additionally, a plurality of island-shaped second welded joints J2, J2... are intermittently formed along the longitudinal direction at predetermined intervals on both sides of the first welded joint J1 in the width direction. The second welded joints J2 cooperate with the first welded joint J1 to form the aforementioned hollow portions SP3, SP3 for inserting and fixing the handle member 9 between the auxiliary sheet 3 and the base sheet 2. Therefore, as shown in FIG. 2B , the second welded joint J2 joins the auxiliary sheet 3, the base sheet 2, and the two fiber bundles 5, 5 located on the upper side in the thickness direction, but does not join the two fiber bundles 5, 5 located below them, or the strip sheet 7 located further below them. The welded joints J1, J2, J2... are formed, for example, by ultrasonic welding.

[0048] <<<<Manufacturing of Web Member 1 >>> The web member 1 is manufactured by a manufacturing apparatus 10. In the manufacturing apparatus 10, the web member 1 is manufactured by being cut to a product size by a cutting mechanism 30 (described later) provided in roughly the final process. Figure 3 is a schematic diagram of a semi-finished product 1a, which is the state of the web member 1 before cutting.

[0049] 3 shows a semi-finished product 1a in which all components 3, 2, 5, 5, 5, 5, 7 of the web member 1, such as the base sheet 2 and fiber bundles 5, have already been laminated and welded together, but have not yet been separated into individual web members 1. In other words, the continuous web member 1a is in a state in which portions 1U, 1U... corresponding to the web members 1, 1... are continuously aligned in the conveying direction of the production line. More specifically, the auxiliary sheet 3, the base sheet 2, and the strip sheet 7 are each in a continuous sheet state in the conveying direction, and each of the fiber bundles 5, 5... is also in a continuous state in the conveying direction. Hereinafter, the continuous web member 1a including tows continuous in the conveying direction (MD direction) will be referred to as the "semi-finished product 1a," and the portion 1U of the semi-finished product 1a corresponding to the web member 1 will also be referred to as the "unit semi-finished product 1U."

[0050] In this embodiment, the semi-finished product 1a is transported in a so-called "lateral flow" transport mode. That is, the semi-finished product 1a is transported with the direction corresponding to the width direction of the web member 1, which is the product, facing the transport direction. Therefore, the cut edges formed by cutting the semi-finished product 1a at the product pitch P1 in the transport direction become the widthwise edge of the web member 1. Furthermore, since the fiber direction of the tows of each fiber bundle 5, 5... in the semi-finished product 1a is aligned with the transport direction, the tows are also cut when cut at the product pitch P1.

[0051] The manufacturing apparatus (web member manufacturing apparatus) 10 will be described below. In the following description, the width direction of the semi-finished product 1a (the width direction of the web member 1) will also be referred to as the "CD direction," and of the two directions perpendicular to the CD direction, the direction in which the semi-finished product 1a (web member 1) continues will also be referred to as the "MD direction." The MD direction also refers to the transport direction of the semi-finished product 1a. Furthermore, the thickness direction of the semi-finished product 1a, the CD direction, and the MD direction are perpendicular to one another.

[0052] Fig. 4A is a schematic side view of the manufacturing apparatus 10 of this embodiment, and Fig. 4B is a view taken along the line B-B in Fig. 4A. Fig. 5 is a view taken along the line C-C in Fig. 4A. For convenience, the configuration is appropriately omitted in these figures and other figures used in the following description.

[0053] The manufacturing apparatus 10 includes an upstream conveying mechanism 20 that conveys the semi-finished product 1a, a cutting mechanism 30 that cuts (segments) the semi-finished product 1a conveyed by the upstream conveying mechanism 20 into individual web members 1, and a downstream conveying mechanism 40 that conveys the individual web members 1 cut at product pitch 1P by the cutting mechanism 30 in the MD direction. The manufacturing apparatus 10 may also include various sensors and control units that monitor the status of various devices such as the conveying mechanisms 20 and 40. For example, the control unit controls the operation of the various devices, the conveying mechanisms 20 and 40, and the cutting mechanism 30 based on detection signals transmitted from the sensors, etc., so that the semi-finished product 1a is sequentially cut at product pitch P1 to produce single-sheet web members 1.

[0054] By manufacturing the web member 1 using a manufacturing method including the following steps, it is possible to improve the manufacturing efficiency of the web member 1a while reducing the risk of the tow fibers sticking together at the cut surface when the semi-finished product 1a is cut.

[0055] The web member 1 is manufactured by a manufacturing method including an upstream conveying process in which an upstream conveying mechanism 20 conveys semi-finished products 1a including continuous tows in the MD direction, a cutting process in which a cutting mechanism 30 cuts the semi-finished products 1a conveyed by the upstream conveying mechanism, and a downstream conveying process in which a downstream conveying mechanism 40 conveys the web member 1 cut at a product pitch P1 by the cutting mechanism 30 in the MD direction. The cutting mechanism 30 includes an upper roll (second roll) 31a and a lower roll (first roll) 31b whose outer peripheral surfaces face each other. At least the lower roll 31b includes a cutting blade 31bs, and the longitudinal direction of the lower cutting blade 31bs is inclined with respect to the rotation center axis C31b of the lower roll 31b when viewed in the radial direction of the lower roll 31b. The cutting mechanism 30 cuts the semi-finished product 1a while transporting the semi-finished product 1a in the MD direction, and cuts the semi-finished product 1a while sliding the semi-finished product 1a relative to the transport surface of the downstream transport mechanism 40.

[0056] The mechanisms 20, 30, and 40 of the manufacturing apparatus 10 and their respective processes are described below. <Upstream Conveying Process> The upstream conveying mechanism 20 is disposed upstream of the cutting mechanism 30 in the MD direction and conveys the semi-finished product 1a toward the cutting mechanism 30. The upstream conveying mechanism 20 includes a lower belt conveyor (lower conveying section) 21 and an upper belt conveyor (upper conveying section) 22 located above the lower belt conveyor 21. The upstream conveying mechanism 20 supports the underside of the semi-finished product 1a on the lower belt conveyor 21, while the upper belt conveyor 22 (endless belt 27) conveys the semi-finished product 1a in a state in which it is in contact with the semi-finished product 1a. In other words, the semi-finished product 1a is sandwiched between the lower belt conveyor 21 and the upper belt conveyor 22 for conveyance.

[0057] The lower belt conveyor 21 has a pair of rollers 23, 23 arranged side by side in the MD direction, and an endless belt 24 wound around the pair of rollers 23, 23. At least one roller 23 of the pair of rollers 23, 23 is driven to rotate by a servo motor serving as a drive source, whereby the outer peripheral surface of the endless belt 24 serves as a conveying surface to convey the semi-finished product 1a downstream in the MD direction.

[0058] Similar to the lower belt conveyor 21, the upper belt conveyor 22 has a pair of rollers 26, 26 arranged side by side in the MD direction, and an endless belt 27 wound around the pair of rollers 26, 26. At least one roller 26 of the pair of rollers 26, 26 is driven to rotate by a servo motor serving as a drive source, whereby the outer peripheral surface of the endless belt 24 serves as a conveying surface to convey the semi-finished products 1a downstream in the MD direction. The endless belt 27 of the upper belt conveyor 22 rotates in tandem with the conveying speed of the lower belt conveyor 21.

[0059] However, the number of rollers 23, 26 is not limited to a pair. For example, three rollers 23, 26 may be provided to rotate the endless belts 24, 27 in a substantially triangular orbit. The upper belt conveyor 22 may receive driving force for its rotation from a servo motor that is the drive source of the lower belt conveyor 21 via an appropriate power transmission mechanism such as a gear train or a winding transmission device, or a separate servo motor may be provided for driving the upper belt conveyor 22 in rotation, and the servo motor may be synchronized with the transport operation of the lower belt conveyor 21.

[0060] As in this embodiment, it is preferable that the upstream conveying mechanism 20 convey the semi-finished product 1a while sandwiched between the lower belt conveyor 21 and the upper belt conveyor 22. The semi-finished product 1a (web member 1) comprising the tow fiber bundle is a soft material and therefore tends to spread in the thickness direction. Therefore, by sandwiching the semi-finished product 1a between the lower belt conveyor 21 and the upper belt conveyor 22, the semi-finished product 1a can be conveyed to the cutting mechanism 30 downstream in the MD direction in a thinned state. The behavior of the cutting blades (31as, 31bs) crushing the semi-finished product 1a and contacting it in the rotational direction of the cutting blades (31as, 31bs) prior to cutting can be reduced by pressing the semi-finished product 1a in the thickness direction to thin it, rather than by spreading it in the thickness direction. Furthermore, this reduces the risk of the cutting position of the semi-finished product 1a becoming distorted or the force applied to the semi-finished product 1a being lost from the cutting blades (31as, 31bs), making it easier to cut the semi-finished product 1a. Therefore, by conveying the semi-finished product 1a while sandwiched between the lower belt conveyor 21 and the upper belt conveyor 22, the semi-finished product 1a is conveyed in a thinned state and conveyed toward the cutting mechanism 30, making it easier to cut the semi-finished product 1a in the cutting mechanism 30. In order to improve the stability of the cutting operation in the cutting mechanism 30, it is preferable that the outer peripheral surfaces of the endless belt 24 of the lower belt conveyor 21 and the endless belt 27 of the upper belt conveyor 22 are arranged to face each other in the upstream conveying mechanism 20, and that these endless belts 24, 27 pinch (press) the semi-finished product 1a located between their outer peripheral surfaces from both sides in the thickness direction.

[0061] <Cutting Process> The cutting mechanism 30 cuts the semi-finished product 1a conveyed by the upstream conveying mechanism 20 at a product pitch P1 to form the web member 1. As shown in Figures 4A and 5, the cutting mechanism 30 includes an upper roll 31a and a lower roll 31b. The upper roll 31a and the lower roll 31b are equipped with a drive source such as a motor and a reverse drive transmission means such as gears, and are rotating bodies that are driven to rotate in the circumferential directions Dca and Dcb about the upper rotation central axis C31a and the lower rotation central axis C31b, respectively. The upper roll 31a and the lower roll 31b are arranged with the axial directions of the upper rotation central axis C31a and the lower rotation central axis C31b, respectively, facing the CD direction, with their outer circumferential surfaces facing each other.

[0062] The outer peripheral surface of the upper roll 31a is provided with an upper cutting blade 31as, which is an acute cutting edge protruding outward from the outer peripheral surface of the upper roll 31a. The outer peripheral surface of the lower roll 31b is provided with a lower cutting blade 31bs, which is an acute cutting edge protruding outward from the outer peripheral surface of the upper roll 31a.

[0063] Fig. 6 is a schematic diagram illustrating the upper cutting blade 31as and the lower cutting blade 31bs of the cutting mechanism 30. Note that Fig. 6 omits the semi-finished product 1a and the web member 1. Fig. 4B also shows the lower roll 31b in the state (d) of Fig. 6.

[0064] The cutting mechanism 30 passes the semi-finished product 1a conveyed from the upstream conveying mechanism 20 through the roll gap between the upper roll 31a and the lower roll 31b, and then conveys the semi-finished product 1a in the MD direction by rotating the upper roll 31a and the lower roll 31b while sandwiching the semi-finished product 1a between the upper roll 31a and the lower roll 31b, cutting the semi-finished product 1a. Specifically, first, the rotation of the rolls 31a and 31b brings the upper cutting blade 31as and the lower cutting blade 31bs closer to each other as shown in states (a) to (c). Then, the rotation of the rolls 31a and 31b brings the upper cutting blade 31as and the lower cutting blade 31bs closer to each other as shown in state (d). State (d) is the point where the upper cutting blade 31as and the lower cutting blade 31bs intersect, where the semi-finished product 1a is sandwiched between them, generating shear stress that breaks the semi-finished product 1a at that point, thereby cutting the semi-finished product 1a. The semi-finished product 1a is then cut by a so-called shear cut. Then, as the rolls 31a and 31b rotate, the upper cutting blade 31as and the lower cutting blade 31bs separate, as shown in states (e) to (g). Then, as the rolls 31a and 31b rotate, states (a) to (g) are repeated again, allowing the semi-finished product 1a to be continuously cut.

[0065] Typically, for the sake of production efficiency, cutting the semi-finished product 1a at the product pitch P1 during the manufacture of the web member 1 is preferably performed, for example, while conveying the semi-finished product 1a with a roll equipped with a blade. However, because the tow fibers are conventionally thermoplastic fibers, if the cutting position (the widthwise end of the web member 1) of the semi-finished product 1a is cut linearly in one go, there is a risk that the tow fibers will be welded or crimped together due to the heat and pressure applied during cutting. If the tow fibers are stuck together, the widthwise end of the web member 1 may close in a sealed state or form a clump, which may impair the dust trapping function of the cleaning member when used as a cleaning tool. Note that the state in which the tow fibers are stuck together refers to a state in which the tow fibers are welded or crimped together.

[0066] In contrast, in the cutting mechanism 30 of this embodiment, the upper roll 31a is equipped with an upper cutting blade 31as, and the longitudinal direction of the upper cutting blade 31as is inclined with respect to the upper rotation central axis C31a of the upper roll 31a when viewed in the radial direction of the upper roll 31a. Furthermore, the lower roll 31b is equipped with a lower cutting blade 31bs, and the longitudinal direction of the lower cutting blade 31b is inclined with respect to the lower rotation central axis C31b of the lower roll 31b when viewed in the radial direction of the lower roll 31b. Furthermore, in the cutting mechanism 30, the semifinished product 1a is cut while being conveyed in the MD direction and while the semifinished product 1a is slid relative to the conveying surface of the downstream conveying mechanism 40 (downstream belt conveyor 41).

[0067] Specifically, as shown in Fig. 5, when viewed in the radial direction of the upper roll 31a, the longitudinal direction of the upper cutting blade 31as is inclined by an angle θa with respect to the upper rotation center axis C31a of the upper roll 31a. When viewed in the radial direction of the lower roll 31b, the longitudinal direction of the lower cutting blade 31b is inclined by an angle θb with respect to the lower rotation center axis C31b of the lower roll 31b. The angles θa and θb are 0°<θa<90° and 0°<θb<90°. It is preferable that the angles θa and θb are 0°<θa<10° and 0°<θb<10°. It is more preferable that the angles θa and θb are 5°<θa<10° and 5°<θb<10°.

[0068] 7A is an enlarged view of portion X in FIG. 4B. FIG. 7B is a diagram illustrating the cutting process of the semifinished product 1a in the state of FIG. 7A. FIG. 7A is a view of the lower roll 31b viewed from the semifinished product 1a side in a state (state (d) in FIG. 6) in which the upper cutting blade 31as of the upper roll 31a and the cutting blade 31bs of the lower roll 31b are closest to each other at the center Pn in the CD direction of the semifinished product 1a at the center Pn in the width direction of the semifinished product 1a. Note that while FIG. 7A only shows the lower roll 31b, the upper roll 31a also has an upper cutting blade 31as that faces the lower cutting blade 31bs of the lower roll 31b. In the state shown in FIG. 7A, the upper roll 31a and the lower roll 31b are configured symmetrically with respect to the semifinished product 1a.

[0069] As shown in Fig. 7A, the lower cutting blade 31bs of the lower roll 31b is inclined by θb with respect to the lower rotation central axis C31b of the lower roll 31b. Because the lower cutting blade 31bs is inclined with respect to the lower rotation central axis C31b (the upper cutting blade 31as is inclined with respect to the upper rotation central axis C31a), when the lower roll 31b rotates, the semifinished product 1a is first cut from the end Ps on the other end side in the CD direction. Then, as the lower roll 31b rotates, the cutting of the semifinished product 1a progresses sequentially along the direction of arrow y. As shown in Fig. 7B, the other end side of the semifinished product 1a in the CD direction is cut, and a portion including the end Pe on one end side in the CD direction (a region on one side of the center portion Pn in the width direction of the semifinished product 1a) remains continuous. In this way, by rotating both rolls 31a and 31b to cut in sequence from end Ps to end Pe along the CD direction, the area to which heat and pressure are applied at one time during cutting can be made smaller than when the semi-finished product 1a is cut linearly from end to end along the CD direction all at once, thereby reducing the risk of the tow fibers sticking together.

[0070] 7B , while the cutting mechanism 30 is cutting the semi-finished product 1a, the lower cutting blade 31bs is tilted relative to the lower rotation axis C31b, resulting in a portion of the semi-finished product 1a being cut and a portion remaining continuous. Therefore, the downstream conveying mechanism 40, located downstream of the cutting mechanism 30, primarily conveys the cut web member 1a, but also conveys a portion of the semi-finished product 1a downstream. The downstream conveying mechanism 40 allows the semi-finished product 1a to slide relative to its conveying surface, facilitating downstream conveyance. This shortens the contact time between the upper cutting blade 31as and the lower cutting blade 31bs and the cut surface of the semi-finished product 1a, thereby reducing the risk of tow fibers sticking together at the cut surface. Furthermore, the semi-finished product 1a is cut under tension, facilitating cutting by the cutting mechanism 30. The relative sliding between the conveying surface of the downstream conveying mechanism 40 and the semi-finished product 1a can be caused by frictional force between the conveying surface of the downstream conveying mechanism 40 and the semi-finished product 1a.

[0071] In this way, the cutting mechanism 30 cuts the semi-finished product 1a while transporting it, thereby improving the manufacturing efficiency of the web member 1 while reducing the risk of the tow fibers sticking together at the cut surface.

[0072] Furthermore, as shown in FIGS. 4B and 7A , it is preferable that the lower rotation center axis C31b (upper rotation center axis C31a) of the lower roll 31b (upper roll 31a) is inclined with respect to the CD direction (direction perpendicular to the MD direction). Even when the longitudinal direction of the lower cutting blade 31bs of the lower roll 31b is inclined with respect to the lower rotation center axis C31b of the lower roll 31b when viewed in the radial direction of the lower roll 31b, the web member 1 can be easily cut in a desired shape and at a desired position. In this embodiment, the lower rotation center axis C31b of the lower roll 31b is inclined by θb with respect to the CD direction, and the lower cutting blade 31bs of the lower roll 31b is aligned with the CD direction and substantially parallel to the CD direction. This allows the shape of the web member 1 after cutting to be a substantially rectangular shape with the width direction and longitudinal direction perpendicular to each other.

[0073] The semi-finished product 1a is made of a soft, expandable material. Because the semi-finished product 1a is soft and expands easily in the thickness direction, cutting the semi-finished product 1a in its current state can result in unstable conveyance and difficulty in accurately cutting the product at the desired position. Therefore, it is preferable to cut the semi-finished product 1a in the cutting mechanism 30 while the lower cutting blade 31bs, the circumferential surface of the lower roll 31b, and the circumferential surface of the upper roll 31a are in contact with the semi-finished product 1a. Figure 8 is a diagram illustrating the semi-finished product 1a in the state (d) of Figure 6. In this embodiment, as shown in Figure 8, the semi-finished product 1a is cut while the upper roll 31a, the upper cutting blade 31as, the lower roll 31b, and the lower cutting blade 31b are in contact with the semi-finished product 1a. That is, in this embodiment, when the upper cutting blade 31as and the lower cutting blade 31bs are in contact with the semi-finished product 1a to cut it, the semi-finished product 1a is in contact with the upper roll 31a and the lower roll 31b upstream of the upper cutting blade 31as and the lower cutting blade 31bs in the MD direction, and the semi-finished product 1a is sandwiched between the upper roll 31a and the lower roll 31b. As a result, the peripheral surfaces of the upper roll 31a and the lower roll 31b press the semi-finished product 1a prior to cutting by the cutting mechanism 30, which makes it easier to keep the amount of semi-finished product 1a conveyed from the upstream conveying mechanism 20 constant and makes it easier to cut the semi-finished product 1a.

[0074] As described above, when viewed in the radial direction of the lower roll 31b (upper roll 31a), the longitudinal direction of the lower cutting blade 31bs (upper cutting blade 31as) of the lower roll 31b (upper roll 31a) is inclined with respect to the lower rotation central axis C31b (upper rotation central axis C31a). This means that when the upper cutting blade 31as and the lower cutting blade 31bs are in contact with the semi-finished product 1a to cut it, the semi-finished product 1a is in contact with the upper roll 31a and the lower roll 31b on both sides of the upper cutting blade 31as and the lower cutting blade 31bs in the CD direction, and the semi-finished product 1a is sandwiched between the upper roll 31a and the lower roll 31b. This makes it easier to maintain a constant amount of semi-finished product 1a conveyed from the upstream conveying mechanism 20, facilitating cutting of the semi-finished product 1a.

[0075] <Downstream Conveying Process> The downstream conveying mechanism 40 is disposed downstream in the MD direction from the cutting mechanism 30. The downstream conveying mechanism 40 includes a downstream belt conveyor 41, an air ejection device 45, and a sensor 46.

[0076] The downstream belt conveyor 41 conveys the web member 1 cut at the product pitch P1 in the MD direction. The downstream belt conveyor 41 has a pair of rollers 43, 43 arranged side by side in the MD direction, and an endless belt 44 wound around the pair of rollers 43, 43. At least one roller 43 of the pair of rollers 43, 43 is driven and rotated by a servo motor serving as a drive source, thereby conveying the web member 1 downstream in the MD direction using the outer circumferential surface of the endless belt 44 as a conveying surface. However, the number of rollers 43 is not limited to a pair. For example, three rollers 43 may be provided, causing the endless belt 44 to rotate in a substantially triangular orbit.

[0077] As shown in FIG. 4A , it is preferable that the downstream belt conveyor 41 (downstream conveying mechanism 40) conveys the web member 1 while supporting only the lower side. That is, unlike the upstream conveying mechanism 20, which conveys the semi-finished product 1a sandwiched between the lower belt conveyor 21 and the upper belt conveyor 22, the downstream conveying mechanism 40 supports only the lower side of the web member 1 with the downstream belt conveyor 41 supporting the web member 1 without pressing the web member 1 from above. This makes it easier to open the fiber bundles 5 of the web member 1 by receiving air resistance, etc. This also makes it easier to maintain the opened state of the fiber bundles 5 of the web member 1, making it easier to make the web member 5 fluffy and soft. As a result, it becomes easier to function as a cleaning tool.

[0078] Because the web member 1 and the components included in the web member 1 are soft and lightweight, there is a risk that the web member 1 may be lifted up or only the fibers on the downstream surface of the web member 1 in the MD direction may be excessively opened due to a headwind (headwind) that the web member 1 receives while being transported by the downstream transport mechanism 40. For this reason, it is more preferable that the downstream transport mechanism 40 be equipped with an air jetting device 45 (air blow nozzle) that jets air toward the web member 1 that is transported while supported by the downstream belt conveyor 41 (downstream transport mechanism 40). By having the air jetting device 45 blow air toward the web member 1 being transported by the downstream belt conveyor 41, it becomes easier to prevent the web member 1 from lifting up and reduce the risk of only one side of the web member 1 being excessively opened.

[0079] Furthermore, it is preferable that the downstream conveying mechanism 40 (downstream belt conveyor 41) does not have a suction mechanism on the conveying surface. When the weight of the object (conveyed object) to be conveyed is light, such as the web member 1, the object tends to float during conveyance, so it is common to provide a suction device on the conveying surface to ensure stable conveyance of the object. However, because the web member 1 contains fiber bundles made of soft materials such as tow fibers, providing a suction mechanism could cause the tow fibers to be sucked in or become tangled. Therefore, by not providing a suction mechanism on the conveying surface of the downstream conveying mechanism 40, the risk of the tow fibers being sucked in or becoming tangled by the suction mechanism can be reduced.

[0080] Generally, when poor cutting occurs in the cutting mechanism 30, the conveyance intervals of the web member 1 in the downstream conveyance mechanism 40 (downstream belt conveyor 41) tend to become uneven. Therefore, it is preferable that the downstream conveyance mechanism 40 be equipped with a sensor 46 for detecting the conveyance intervals of the web member 1. Detection of the conveyance intervals of the web member 1 by the sensor 46 makes it easy to determine whether the web member 1 has been properly cut.

[0081] In each process, it is preferable that the downstream conveyance speed V4 at which the web member 1 is conveyed in the downstream conveyance mechanism 40 is faster than the cutting conveyance speed V3 at which the semi-finished product 1a is conveyed in the cutting mechanism 30 (V3<V4). By making the downstream conveyance speed V4 faster than the cutting conveyance speed V3, the risk of the web member 1 being stuck in the cutting mechanism 30 after being cut by the cutting mechanism 30 can be reduced compared to when the downstream conveyance speed V4 is slower than the cutting conveyance speed V3. Furthermore, because the conveyance surface of the downstream conveyance mechanism 40 and the semi-finished product 1a slide relative to each other, the cutting mechanism 30 can perform cutting while the semi-finished product 1a is pulled downstream in the MD direction, making it easier to cut the semi-finished product 1a. This makes it easier to reduce the time required to apply heat and pressure to the cut surface and reduces the risk of the tow fibers at the cut surface sticking together.

[0082] Furthermore, with regard to the speeds of each process, it is more preferable that the cutting and conveying speed V3 in the cutting mechanism 30 be faster than the upstream conveying speed V2 at which the semi-finished product 1a is conveyed in the upstream conveying mechanism 20 (V3 > V2). This reduces the risk that the web member 1 will remain in the cutting mechanism 30 after being cut by the cutting mechanism 30, and also makes it easier to cut the semi-finished product 1a because the semi-finished product 1a can be cut while being pulled in the MD direction. As a result, it becomes easier to reduce the time that heat and pressure are applied to the cut surface, and it is possible to reduce the risk that the tow fibers at the cut surface will stick together.

[0083] With regard to the upstream conveying speed V2, the cutting conveying speed V3, and the downstream conveying speed V3, it is preferable that the cutting conveying speed V3 is faster than the upstream conveying speed V2, and it is preferable that the downstream conveying speed V4 is faster than the cutting conveying speed V3 (V2<V3<V4). This reduces the risk of the semi-finished product 1a and the web member 1 getting stuck in the cutting mechanism 30, and allows the semi-finished product 1a to be cut while being tensioned in the MD direction, making cutting by the cutting mechanism 30 easier.

[0084] In addition, if the downstream conveying speed V4 in the downstream conveying mechanism 40 is excessively fast, the semi-finished product 1a or the web member 1 may meander or float up during conveying in the downstream conveying mechanism 40. Therefore, it is more preferable that the difference (V4-V3) between the downstream conveying speed V4 in the downstream conveying mechanism 40 and the cutting conveying speed V3 in the cutting mechanism 30 is smaller than the difference (V3-V2) between the cutting conveying speed V3 in the cutting mechanism 30 and the upstream conveying speed V2 of the upstream conveying mechanism 20 (V4-V3<V3-V2). By making the difference (V4-V3) between the downstream conveying speed V4 and the cutting conveying speed V3 smaller than the difference (V3-V2) between the cutting conveying speed V3 and the upstream conveying speed V2 (V4-V3<V3-V2), the risk of the semi-finished product 1a or the web member 1 meandering or the risk of the web member 1 floating up can be reduced more than when the difference (V4-V3) between the downstream conveying speed V4 and the cutting conveying speed V3 is larger than the difference (V3-V2) between the cutting conveying speed V3 and the upstream conveying speed V2 (V4-V3>V3-V2).

[0085] Furthermore, the thickness of the semi-finished product 1a (T3 in FIG. 8) at the time when the semi-finished product 1a and the lower roll 31b in the cutting mechanism 30 come into contact is preferably half or less (T3≦T1×½) of the thickness (T1) of the web member 1 in the downstream conveying mechanism 40. The thickness (T1) of the web member 1 in the downstream conveying mechanism 40 is approximately the same as the thickness T1 (see FIG. 2B) of the web member 1 as a product. In the case of a soft, spreadable material like the semi-finished product 1a, the thinner the thickness, the easier it is to cut. Therefore, by setting the thickness (T3) of the semi-finished product 1a at the time when the semi-finished product 1a and the lower roll 31b in the cutting mechanism 30 come into contact with each other to be equal to or less than half (T3≦T1×½) of the thickness (T1) of the web member 1 in the downstream conveying mechanism 40, it is possible to reduce the behavior of the cutting blades (31as, 31bs) crushing the semi-finished product 1a while contacting it in the rotational direction of the cutting blades (31as, 31bs) prior to cutting, compared to when the thickness (T3) of the semi-finished product 1a at the time when the semi-finished product 1a and the lower roll 31b in the cutting mechanism 30 come into contact with each other is greater than half (T3>T1×½) of the thickness (T1) of the web member 1 in the downstream conveying mechanism 40. This also reduces the risk of the cutting position for the semi-finished product 1a becoming distorted or the force applied to the semi-finished product 1a being lost from the cutting blades (31as, 31bs). This makes it easier for the cutting mechanism 30 to cut the semi-finished product 1a.

[0086] <<<<Modifications of Cutting Mechanism 30>>> In the above-described embodiment, both rolls 31a, 31b of the cutting mechanism 30 are equipped with cutting blades 31as, 31bs, respectively, and the semi-finished product 1a is sandwiched between the upper cutting blade 31as and the lower cutting blade 31bs to generate shear stress and cut the semi-finished product 1a by so-called shear cutting, but this is not limited to this.

[0087] At least one of the pair of rolls 31a, 31b of the cutting mechanism 30 may be equipped with a cutting blade. For example, FIG. 9 is a schematic diagram illustrating a modified example of the cutting mechanism 30. FIG. 9 illustrates a configuration in which only the upper roll (first roll) 31a is equipped with an upper cutting blade 31as, and the lower roll (second roll) 31b is an anvil roll without a cutting blade. The configuration shown in FIG. 9 is a so-called push-cutting method in which the upper cutting blade 31as of the upper roll 31a and the lower roll 31b are brought into contact with each other via the semi-finished product 1a by rotation of the upper roll 31a and the lower roll 31b, thereby cutting the semi-finished product 1a. In the cutting mechanism 30 shown in FIG. 9, the longitudinal direction of the upper cutting blade 31as is inclined with respect to the upper rotation center axis C31a of the upper roll 31a (not shown) when viewed in the radial direction of the upper roll 31a. In this cutting mechanism 30, the semi-finished product 1a is cut while being conveyed in the MD direction and while the conveying surface of the downstream conveying mechanism 40 and the semi-finished product 1a are slid relative to each other, thereby improving the manufacturing efficiency of the web member 1 and reducing the risk of tow fibers sticking together at the cut surface. In the modified example of the cutting mechanism 30 shown in FIG. 9 , only the upper roll 31a is provided with an upper cutting blade 31as, and the lower roll 31b is an anvil roll without a cutting blade, but this is not limited to this. A cutting mechanism 30 in which the upper roll 31a is provided with an upper cutting blade 31as and the lower roll 31b is provided with a lower cutting blade 31bs may also cut the semi-finished product 1a by pressing the upper cutting blade 31as against the lower cutting blade 31bs through the semi-finished product 1a as the upper roll 31a and the lower roll 31b rotate.

[0088] ===Other Embodiments= ...

[0089] For example, the following modifications are possible: In the above-described embodiment, the semi-finished product 1a relating to the web member 1 is shown as an example of the web member, but the present invention is not limited to this. In other words, the present invention is not limited to the above as long as the web member has a plurality of fibers including tows and is continuous in the conveying direction.

[0090] 1 Web member, 1a Semi-finished product (continuous web member), 1U Unit semi-finished product, 2 Base sheet, 2e Both ends, 3 Auxiliary sheet, 3e Both ends, 5 Fiber bundle, 5G Fiber bundle member, 7 Strip sheet, 9 Handle member, 9a Insertion section, 10 Manufacturing apparatus (web member manufacturing apparatus), 20 Upstream conveying mechanism, 21 Lower belt conveyor (lower conveying section), 22 Upper belt conveyor (upper conveying section), 23 Roller, 24 Endless belt, 26 Roller, 27 Endless belt, 30 Cutting mechanism, 31a Upper roll (second roll), 31as Upper cutting blade, 31b Lower roll (first roll), 31bs Lower cutting blade (cutting blade), 40 Downstream conveying mechanism, 41 Downstream belt conveyor, 43 Roller, 44: Endless belt, 45: Air ejection device, 46: Sensor, C31a: Upper rotation central shaft, C31b: Lower rotation central shaft (rotation central shaft)

Claims

1. A web member manufacturing apparatus comprising: an upstream conveying mechanism for conveying a continuous web member including a tow that is continuous in a conveying direction; a cutting mechanism for cutting the continuous web member conveyed by the upstream conveying mechanism; and a downstream conveying mechanism for conveying in the conveying direction the web member cut into product pitches by the cutting mechanism, wherein the cutting mechanism comprises a first roll and a second roll whose outer circumferential surfaces face each other, at least the first roll has a cutting blade, the longitudinal direction of the cutting blade is inclined with respect to the central axis of rotation of the first roll as viewed in the radial direction of the first roll, and the cutting mechanism cuts the continuous web member while conveying the continuous web member in the conveying direction and while sliding the conveying surface of the downstream conveying mechanism relative to the continuous web member.

2. A web member manufacturing apparatus as described in claim 1, characterized in that the downstream conveying speed at which the web member is conveyed in the downstream conveying mechanism is faster than the cutting conveying speed at which the continuous web member is conveyed in the cutting mechanism.

3. A web member manufacturing apparatus according to claim 2, characterized in that the cutting and conveying speed is faster than the upstream conveying speed at which the continuous web member is conveyed in the upstream conveying mechanism.

4. An apparatus for manufacturing a web member according to claim 3, characterized in that the difference between the downstream conveying speed and the cutting conveying speed is smaller than the difference between the cutting conveying speed and the upstream conveying speed.

5. An apparatus for manufacturing a web member according to any one of claims 1 to 4, characterized in that the downstream transport mechanism is provided with a sensor for detecting the transport interval of the web member.

6. An apparatus for manufacturing a web member according to any one of claims 1 to 4, characterized in that in the downstream transport mechanism, the web member is transported while only the lower side of the web member is supported.

7. A web member manufacturing apparatus as set forth in claim 6, further comprising an air blowing device for blowing air toward said web member supported by said downstream transport mechanism.

8. An apparatus for manufacturing a web member according to any one of claims 1 to 4, characterized in that the downstream transport mechanism does not have a suction mechanism on the transport surface.

9. A web material manufacturing apparatus as claimed in any one of claims 1 to 4, characterized in that the upstream conveying mechanism comprises an upper conveying section and a lower conveying section, and conveys the continuous web material while sandwiched between the upper conveying section and the lower conveying section.

10. An apparatus for manufacturing a web member according to any one of claims 1 to 4, characterized in that the central axis of rotation of the first roll is inclined with respect to a direction perpendicular to the conveying direction.

11. An apparatus for manufacturing a web member as described in any one of claims 1 to 4, characterized in that in the cutting mechanism, the cutting blade, the peripheral surface of the first roll, and the peripheral surface of the second roll are in contact with the continuous web member, and the apparatus for manufacturing a web member is characterized in that the cutting mechanism cuts the continuous web member while the cutting blade, the peripheral surface of the first roll, and the peripheral surface of the second roll are in contact with the continuous web member.

12. A web member manufacturing apparatus as described in claim 11, characterized in that the thickness of the continuous web member at the time when the continuous web member and the first roll come into contact is less than half the thickness of the web member in the downstream conveying mechanism.

13. A method for manufacturing a web member, comprising: an upstream conveying step of conveying, in an upstream conveying mechanism, a continuous web member including tows continuous in a conveying direction; a cutting step of cutting, in a cutting mechanism, the continuous web member conveyed by the upstream conveying mechanism; and a downstream conveying step of conveying, in the conveying direction, the web member cut into product pitches by the cutting mechanism, wherein the cutting mechanism comprises a first roll and a second roll whose outer circumferential surfaces face each other; at least the first roll is provided with a cutting blade; as viewed in the radial direction of the first roll, the longitudinal direction of the cutting blade is inclined with respect to the central axis of rotation of the first roll; and the cutting mechanism cuts the continuous web member while conveying it in the conveying direction, and cuts the continuous web member while sliding the conveying surface of the downstream conveying mechanism relative to the continuous web member.

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