JP6542595B2 - Cleaning tool - Google Patents
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- JP6542595B2 JP6542595B2 JP2015121946A JP2015121946A JP6542595B2 JP 6542595 B2 JP6542595 B2 JP 6542595B2 JP 2015121946 A JP2015121946 A JP 2015121946A JP 2015121946 A JP2015121946 A JP 2015121946A JP 6542595 B2 JP6542595 B2 JP 6542595B2
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- 238000004140 cleaning Methods 0.000 title claims description 51
- 239000004745 nonwoven fabric Substances 0.000 claims description 87
- 238000010438 heat treatment Methods 0.000 claims description 71
- 239000000835 fiber Substances 0.000 claims description 40
- 238000002844 melting Methods 0.000 claims description 26
- 230000008018 melting Effects 0.000 claims description 26
- 239000000463 material Substances 0.000 claims description 21
- 229920000728 polyester Polymers 0.000 claims description 19
- 230000005855 radiation Effects 0.000 claims description 18
- 229920003002 synthetic resin Polymers 0.000 claims description 15
- 239000000057 synthetic resin Substances 0.000 claims description 15
- 230000004927 fusion Effects 0.000 description 31
- 230000015572 biosynthetic process Effects 0.000 description 22
- 230000007423 decrease Effects 0.000 description 11
- 239000000853 adhesive Substances 0.000 description 8
- 230000001070 adhesive effect Effects 0.000 description 8
- 239000000155 melt Substances 0.000 description 7
- 230000035699 permeability Effects 0.000 description 7
- 238000000034 method Methods 0.000 description 6
- 239000000758 substrate Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 3
- 239000006260 foam Substances 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 238000004904 shortening Methods 0.000 description 2
- 238000007664 blowing Methods 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 238000010411 cooking Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
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- Cleaning Implements For Floors, Carpets, Furniture, Walls, And The Like (AREA)
Description
本発明は、弾性基材の外面に、可塑性の合成樹脂繊維で構成された不織布シートを接着して構成された洗浄具に関する。 The present invention relates to a cleaning tool configured by bonding a non-woven sheet made of a plastic synthetic resin fiber to the outer surface of an elastic base.
従来、この種の洗浄具としては、合成樹脂繊維をランダム配列させて積層してなるウェブをニードルパンチ等で繊維同士を交絡させて製造される不織布シートを、直方体状に構成されたスポンジ等の弾性基材の外面に対して接着剤や熱融着等により接着して構成され、その不織布シートの表面を摺擦させて、食器、調理器具、洗面台、トイレ、浴槽等の被洗浄物を洗浄するのに利用される洗浄具が知られている（例えば、特許文献１を参照。）。 Conventionally, as a cleaning tool of this type, a non-woven sheet produced by interlacing fibers with a web formed by arranging synthetic resin fibers randomly and laminating them with a needle punch etc. is a sponge etc. The surface of the non-woven sheet is rubbed by bonding to the outer surface of the elastic base material by an adhesive or heat fusion, etc., and the cleaning object such as dishes, cooking utensils, wash basins, toilets, baths etc. A cleaning tool used for cleaning is known (see, for example, Patent Document 1).
このように不織布シートの表面を洗浄面とする洗浄具では、不織布シートの表面が、ざらついた被洗浄物に摺擦されたり、鋭利な箸やフォークの先端に引っ掛けられたりすることで、縮みや毛羽立ち等の損傷が進行して、短寿命化につながるという問題が生じる。 As described above, in the cleaning tool having the surface of the non-woven fabric sheet as the cleaning surface, the surface of the non-woven fabric sheet is shrunk by being rubbed against the object to be cleaned or hooked on the tip of a sharp edge or fork. Damage such as fuzzing progresses, leading to a problem of shortening the life.
このような不織布シートの使用に伴う損傷を抑制する方法としては、当該不織布シートに燃焼ガスなどの熱風などを吹きあてて全体を加熱する加熱処理を施して、合成樹脂繊維同士を熱融着により結合させる方法がある。 As a method of suppressing the damage accompanying use of such a nonwoven fabric sheet, the heating process which heats the whole by blowing hot air etc., such as combustion gas, to the said nonwoven fabric sheet concerned is performed, and synthetic resin fibers are heat-sealed. There is a way to combine.
しかしながら、不織布シート全体に加熱処理を施すと、不織布シート全体に合成樹脂繊維の一部が溶融してなる溶融部が形成されて、不織布シートの柔軟性が損なわれる。すると、使用感が低下する上に、弾性基材への接着の際に、当該弾性基材の外面に対して馴染み難くなって接着不良が生じる恐れがある。 However, when the entire nonwoven fabric sheet is subjected to heat treatment, a molten portion in which a part of synthetic resin fibers is melted is formed in the entire nonwoven fabric sheet, and the flexibility of the nonwoven fabric sheet is impaired. As a result, the feeling in use decreases, and when adhering to the elastic base material, it is difficult to conform to the outer surface of the elastic base material, which may cause adhesion failure.
更に、不織布シート全体に加熱処理を施すと、弾性基材に接着される不織布シートの裏面が空隙の少ない平坦なものとなるので、接着剤等が浸透し難くなって弾性基材に対する接着性が低下し、結果、弾性基材から不織布シートが剥離し易くなって短寿命化の要因となる。 Furthermore, when the whole nonwoven fabric sheet is subjected to heat treatment, the back surface of the nonwoven fabric sheet bonded to the elastic substrate becomes flat with few voids, so that the adhesive and the like hardly penetrate and the adhesiveness to the elastic substrate is improved. As a result, the non-woven fabric sheet is easily peeled off from the elastic substrate, which results in shortening of the service life.
このような接着不良や接着性の低下を改善するために、接着方法自身を強固なものとすることが考えられるが、強固な接着を施すことでその接着部が比較的硬い境界面として形成されるために、洗浄具全体がごわついたものとなり、使用感が低下するという問題が生じる。 In order to improve such adhesion failure and adhesion deterioration, it is conceivable to make the bonding method itself strong, but by applying strong bonding, the bonding portion is formed as a relatively hard boundary surface. As a result, the entire cleaning tool becomes cluttered, causing a problem that the feeling in use is reduced.
この実情に鑑み、本発明の主たる課題は、弾性基材の外面に、可塑性の合成樹脂繊維で構成された不織布シートを接着して構成された洗浄具であって、不織布シートの弾性基材への接着性の低下や使用感の低下を回避しながら、不織布シートの表面の使用に伴う縮みや毛羽立ち等の損傷を抑制することができる洗浄具を提供する点にある。 In view of this situation, the main object of the present invention is a cleaning tool configured by bonding a non-woven sheet composed of a plastic synthetic resin fiber to the outer surface of an elastic base, to the elastic base of the non-woven sheet It is an object of the present invention to provide a cleaning tool capable of suppressing damage such as shrinkage and fuzzing caused by the use of the surface of the non-woven fabric sheet while avoiding the decrease in adhesion and the decrease in feeling in use.
本発明の第１特徴構成は、弾性基材の外面に、可塑性の合成樹脂繊維で構成された不織布シートを接着して構成された洗浄具であって、
前記不織布シートの表面が、前記合成樹脂繊維の一部が溶融してなる溶融部が形成された溶融部形成面とされていると共に、
前記不織布シートの裏面が、前記弾性基材に接着される溶融部非形成面とされており、
前記弾性基材に接着される前の不織布シートに対して表面側から輻射熱を照射する輻射式加熱処理により、前記溶融部形成面及び前記溶融部非形成面が形成されており、
前記輻射式加熱処理における前記不織布シートの加熱前に対する加熱後の厚みの収縮幅が０．１ｍｍ〜２．０ｍｍの範囲内に設定されて前記溶融部形成面において複数の前記溶融部が互いに分散して形成されている点にある。
A first feature of the present invention is a cleaning tool constructed by bonding a non-woven sheet composed of a plastic synthetic resin fiber to the outer surface of an elastic base,
The surface of the non-woven fabric sheet is a molten portion forming surface on which a molten portion formed by melting a part of the synthetic resin fiber is formed,
The back surface of the non-woven fabric sheet is a non-melted surface to be bonded to the elastic base material ,
The fused portion forming surface and the fused portion non-formed surface are formed by radiation heat treatment in which radiant heat is irradiated from the surface side to the nonwoven fabric sheet before being bonded to the elastic base material,
The shrinkage width of the thickness after heating relative to that before heating of the non-woven fabric sheet in the radiation heat treatment is set within a range of 0.1 mm to 2.0 mm, and the plurality of melted portions are mutually dispersed on the melted portion forming surface It is in the point where it is formed .
本特徴構成によれば、洗浄時に被洗浄物に摺擦される洗浄面として機能する不織布シートの表面が上記溶融部形成面とされているので、その溶融部形成面を摺擦させて被洗浄物を洗浄する洗浄時において、比較的硬い溶融部が被洗浄物に摺擦されることで研磨力が向上する上に、上記溶融部により繊維間が適度に結合されることで使用に伴う縮みや毛羽立ち等の損傷が抑制され、長寿命化を実現することができる。 According to this feature configuration, the surface of the non-woven fabric sheet that functions as the cleaning surface to be rubbed against the object to be cleaned during cleaning is the above-mentioned melting portion forming surface, so the melting portion forming surface is rubbed to be cleaned At the time of cleaning the object, the relatively hard melted portion is rubbed against the object to be cleaned to improve the polishing power, and the fibers are appropriately connected by the melted portion, which causes shrinkage due to use. In addition, damage such as fuzzing can be suppressed, and life extension can be realized.
一方、弾性基材に接着される不織布シートの裏面が、上記溶融部が形成されることなく合成樹脂繊維が緻密に交絡した状態で維持された溶融部非形成面とされているので、全体での溶融部形成に伴う柔軟性の低下が抑制される。更に、その溶融部非形成面への接着剤等の浸透が良好なものとなって、弾性基材への接着が強力且つ均一なものとなる。よって、簡単な接着を施してその接着部の柔軟性を確保しつつ、弾性基材に対する不織布シートの剥離を抑制することができる。 On the other hand, since the back surface of the non-woven fabric sheet bonded to the elastic base is a fused portion non-formed surface which is maintained in a state in which the synthetic resin fibers are closely entangled without forming the fused portion The decrease in flexibility due to the formation of the molten part of Furthermore, the penetration of the adhesive or the like to the surface on which the molten portion is not formed becomes good, and the adhesion to the elastic substrate becomes strong and uniform. Therefore, peeling of the nonwoven fabric sheet with respect to an elastic base material can be suppressed, applying simple adhesion and securing the pliability of the adhesion part.
従って、本発明により、不織布シートの弾性基材への接着性の低下や使用感の低下を回避しながら、不織布シートの表面の使用に伴う縮みや毛羽立ち等の損傷を抑制することができる洗浄具を提供することができる。
更に、本特徴構成によれば、不織布シートに対し、弾性基材に接着される前の段階で、表面側から遠赤外線ヒータ等により輻射熱を照射する輻射式加熱処理を施すという簡単な構成により、表面には溶融部を形成して溶融部形成面とすると共に、裏面には溶融部の形成を防止して溶融部非形成面とすることができる。
更に、輻射式加熱処理において不織シートの表面側を加熱すると、その表面側の合成樹脂繊維が溶融して収縮することで、不織布シートの厚みが収縮する。要するに、輻射式加熱処理における不織布シートの加熱前に対する加熱後の厚みの収縮幅が大きくなるほど、溶融部形成面における溶融部が占める割合が大きくなるといえる。
そこで、本特徴構成によれば、この不織布シートの加熱前に対する加熱後の厚みの収縮幅が０．１ｍｍ〜２．０ｍｍの範囲内となるように、輻射式加熱処理における加熱条件等を設定するので、溶融部形成面のごわつきや透水性低下を抑制しながら、使用に伴う縮みや毛羽立ち等の損傷を好適に抑制可能な程度に当該溶融部形成面に溶融部を分散形成することができる。
Therefore, according to the present invention, a cleaning tool capable of suppressing damage such as shrinkage and fuzzing with use of the surface of the non-woven sheet while avoiding the decrease in the adhesiveness and the feeling of use of the non-woven sheet to the elastic substrate. Can be provided.
Furthermore, according to the present feature configuration, the non-woven fabric sheet has a simple configuration in which a radiant heat treatment is performed from the surface side to irradiate radiant heat with a far-infrared heater or the like before being bonded to the elastic substrate. While forming a fusion | melting part in the surface and making it a fusion | melting part formation surface, formation of a fusion | melting part can be prevented and a fusion | melting part non-formation surface can be made in a back surface.
Furthermore, when the surface side of the non-woven sheet is heated in the radiation heat treatment, the synthetic resin fibers on the surface side are melted and shrunk, whereby the thickness of the non-woven sheet shrinks. In short, it can be said that the larger the shrinkage width of the thickness after heating of the non-woven fabric sheet before heating in the radiant heat treatment, the larger the ratio of the molten part in the molten part forming surface.
Therefore, according to the present feature configuration, the heating condition and the like in the radiant heat treatment are set so that the shrinkage width of the thickness of the non-woven fabric sheet after heating is within the range of 0.1 mm to 2.0 mm. Therefore, the molten portion can be dispersedly formed on the molten portion forming surface to such an extent that damage such as shrinkage and fuzzing with use can be suitably suppressed while suppressing the stiffness and the permeability decrease of the molten portion forming surface.
本発明の第２特徴構成は、上記第１特徴構成を有する洗浄具において、前記不織布シートの厚みが、１ｍｍ以上３ｍｍ以下の範囲内である点にある。 According to a second aspect of the present invention, in the cleaning tool having the first aspect, the thickness of the non-woven fabric sheet is in the range of 1 mm to 3 mm.
従来の洗浄具では、使用に伴う縮みや毛羽立ち等の損傷を補うべく、不織布シートの厚みは、例えば５ｍｍ程度の比較的分厚いものであった。
しかしながら、本特徴構成によれば、不織布シートの表面の使用に伴う損傷を抑制することができるので、不織布シートの厚みを３ｍｍ以下の範囲内の比較的薄いものとすることができ、これにより、コストダウンを図ることができる上に、比較的ごわつき易い不織布シートの薄型化による柔軟性の向上を図ることができる。更に、不織布シート自体の耐久性を通常使用に耐える程度に確保するためには、不織布シートの厚みは１ｍｍ以上とすることが望ましい。
In the conventional cleaning tool, the thickness of the non-woven fabric sheet is relatively thick, for example, about 5 mm, in order to compensate for damage such as shrinkage and fuzzing with use.
However, according to the present feature configuration, since the damage caused by the use of the surface of the non-woven fabric sheet can be suppressed, the thickness of the non-woven fabric sheet can be made relatively thin within the range of 3 mm or less. In addition to the cost reduction, it is possible to improve the flexibility by thinning the nonwoven sheet which is relatively fragile. Furthermore, in order to ensure the durability of the non-woven fabric sheet itself to an extent that normally withstands use, the thickness of the non-woven fabric sheet is desirably 1 mm or more.
本発明の第３特徴構成は、上記第１又は第２特徴構成を有する洗浄具において、前記溶融部形成面において前記溶融部が形成された溶融部形成層の厚みが、０．０１ｍｍ〜０．２０ｍｍの範囲内である点にある。 According to a third aspect of the present invention, in the cleaning tool having the first or second aspect, the thickness of the molten portion forming layer in which the molten portion is formed on the molten portion forming surface is 0.01 mm to 0.. The point is within the range of 20 mm.
本特徴構成によれば、上記溶融部形成層の厚みが０．０１ｍｍ〜０．２０ｍｍの範囲内であるので、溶融部形成層のごわつきや透水性低下を抑制しながら、使用に伴う縮みや毛羽立ち等の損傷を好適に抑制することができる。
即ち、上記溶融部形成層の厚みが０．０１ｍｍを下回る場合には、繊維間を結合するための溶融部の形成が不十分となり、結果、使用に伴う縮みや毛羽立ち等の損傷の抑制効果を十分に享受することができなくなる。
逆に、上記溶融部形成層の厚みが０．２０ｍｍを上回る場合には、溶融部形成層における溶融部が占める割合が大きくなりすぎてしまい、結果、溶融部形成層のごわつきや透水性低下が問題となる。
According to this feature configuration, since the thickness of the molten portion forming layer is in the range of 0.01 mm to 0.20 mm, the shrinkage and fuzz associated with use are suppressed while suppressing the stiffness and the permeability decrease of the molten portion forming layer. And the like can be suitably suppressed.
That is, when the thickness of the melt portion forming layer is less than 0.01 mm, the formation of the melt portion for bonding the fibers becomes insufficient, and as a result, the effect of suppressing damage such as shrinkage and fuzzing with use You will not be able to fully enjoy it.
On the contrary, when the thickness of the above-mentioned fusion zone formation layer exceeds 0.20 mm, the ratio which the fusion zone occupies in the fusion zone formation layer becomes too large, as a result, stiffness and the permeability decrease of fusion zone formation layer It becomes a problem.
本発明の第４特徴構成は、上記第１〜第３の何れかの特徴構成を有する洗浄具において、前記不織布シートが単一の前記合成樹脂繊維で構成されている点にある。 According to a fourth characterizing feature of the present invention, in the cleaning tool having any of the first to third characterizing features, the non-woven fabric sheet is composed of a single synthetic resin fiber .
本発明の第５特徴構成は、上記第４特徴構成を有する洗浄具において前記不織布シートが、ポリエステル製繊維で構成され、
前記輻射式加熱処理における加熱条件として、加熱温度が３００℃〜５００℃の範囲内に設定され、加熱時間が１秒〜１５秒の範囲内に設定されている点にある。
According to a fifth aspect of the present invention, in the cleaning tool having the fourth aspect, the non-woven fabric sheet is made of polyester fibers,
As heating conditions in the radiation type heat treatment, the heating temperature is set in the range of 300 ° C. to 500 ° C., and the heating time is set in the range of 1 second to 15 seconds.
本特徴構成によれば、融点が２５５℃〜２６５℃程度のポリエステル製繊維で構成された不織布シートの表面側に対し、上記のような加熱温度及び加熱時間の好適な加熱条件で上記輻射式加熱処理を施すことで、溶融部非形成面への輻射熱の影響を好適に抑制して、当該溶融部非形成面の弾性基材への接着性を適当なものに確保しつつ、使用に伴う縮みや毛羽立ち等の損傷を好適に抑制可能な程度に当該溶融部形成面に溶融部を分散形成することができる。 According to this feature configuration, the radiation type heating is performed on the surface side of the non-woven fabric sheet made of polyester fibers having a melting point of about 255 ° C. to 265 ° C. under the preferable heating conditions of the above heating temperature and heating time. By performing the treatment, it is possible to suitably suppress the influence of radiant heat on the surface on which the molten portion is not formed, and to ensure the adhesion of the surface on which the molten portion is not formed to the elastic base material while contracting with use. The fused portion can be dispersedly formed on the fused portion forming surface to such an extent that damage such as fuzzing can be suitably suppressed.
即ち、上記のような効果を得るための輻射式加熱処理における加熱温度は、３００℃〜５００℃の範囲内に設定することが望ましく、また、上記のような効果を得るための輻射式加熱処理における加熱時間は、１秒〜１５秒の範囲内に設定することが望ましい。
上記加熱温度が３００℃を下回る場合、或いは上記加熱時間が１秒を下回る場合には、溶融部形成面のポリエステル繊維を十分に溶融させることができなくなって、繊維間を結合するための溶融部の形成が不十分となり、結果、使用に伴う縮みや毛羽立ち等の損傷の抑制効果を十分に享受することができなくなる。
逆に、上記加熱温度が５００℃を上回る場合、或いは上記加熱時間が１５秒を上回る場合には、溶融部非形成面への輻射熱の影響が問題となる上に、溶融部形成面のポリエステル繊維の溶融が進行して、溶融部形成面における溶融部が占める割合が大きくなりすぎてしまい、結果、溶融部形成面のごわつきや透水性低下が問題となる。
That is, it is desirable to set the heating temperature in the radiant heat treatment to obtain the above effects within the range of 300 ° C. to 500 ° C. Further, the radiant heat treatment to obtain the above effects It is desirable to set the heating time in the range of 1 second to 15 seconds.
When the heating temperature is less than 300 ° C., or when the heating time is less than 1 second, it is not possible to sufficiently melt the polyester fibers of the fusion portion forming surface, and a fusion portion for bonding the fibers As a result, it is impossible to fully enjoy the effect of suppressing damage such as shrinkage and fuzzing accompanying use.
Conversely, if the heating temperature exceeds 500 ° C., or if the heating time exceeds 15 seconds, the effect of radiant heat on the surface on which the molten portion is not formed becomes a problem, and the polyester fiber on the surface on which the molten portion is formed The melting progresses, and the ratio of the molten portion in the molten portion forming surface becomes too large, and as a result, the stiffness of the molten portion forming surface and the decrease in water permeability become problems.
本発明の実施形態について図面に基づいて説明する。
図１及び図２に示すように、本実施形態の洗浄具１０は、横幅が略１２０ｍｍ、縦幅が略６０ｍｍ、厚みが略３０ｍｍの直方体形状に形成されており、一方面側から順に、厚みが略２ｍｍの不織布層１１と、厚みが略１０ｍｍの支持層１２と、厚みが略１８ｍｍのスポンジ層１３とが、互いに接着されて積層してなる３重構造を有する。そして、不織布層１１の支持層１２側とは反対側の面（図２における洗浄具１０の上面）と、スポンジ層１３の支持層１２側とは反対側の面（図２における洗浄具１０の下面）とが、食器、調理器具、洗面台、トイレ、浴槽等の被洗浄物を洗浄する際に、当該被洗浄物に摺擦される洗浄面として機能する。
An embodiment of the present invention will be described based on the drawings.
As shown in FIGS. 1 and 2, the cleaning tool 10 of the present embodiment is formed in a rectangular parallelepiped shape having a width of about 120 mm, a width of about 60 mm, and a thickness of about 30 mm. The nonwoven fabric layer 11 of about 2 mm, the support layer 12 of about 10 mm in thickness, and the sponge layer 13 of about 18 mm in thickness are adhered to each other and have a triple-layered structure. The surface of the non-woven fabric layer 11 opposite to the support layer 12 (the upper surface of the cleaning tool 10 in FIG. 2) and the surface of the sponge layer 13 opposite to the support layer 12 (the cleaning tool 10 in FIG. The lower surface functions as a cleaning surface to be rubbed against the object to be cleaned when cleaning the object to be cleaned such as dishes, cookware, a wash basin, a toilet, a bath and the like.
支持層１２は、後述するスポンジ層１３よりも反発弾性が高いウレタンフォームで構成されており、このような支持層１２が設けられていることで、洗浄具１０全体の弾力性と保形性が向上されている。
尚、本実施形態では、この支持層１２が、外面に後述する不織布シートＡが接着される弾性基材Ｂとして機能する。
The support layer 12 is made of urethane foam having higher resilience than the sponge layer 13 described later, and by providing such a support layer 12, the elasticity and shape retention of the entire cleaning tool 10 can be improved. It has been improved.
In the present embodiment, the support layer 12 functions as an elastic base material B to which a non-woven fabric sheet A described later is adhered to the outer surface.
スポンジ層１３は、細かい連続気泡を有し上記支持層１２よりも反発弾性が低く柔軟なウレタンフォームで構成されており、このようなスポンジ層１３が設けられることで、スポンジ層１３の洗浄面での吸排水性と柔軟性が確保されている。 The sponge layer 13 is made of a flexible urethane foam having fine open cells and having lower impact resilience than the support layer 12 and is provided with such a sponge layer 13. Suction and drainage of water and flexibility are secured.
不織布層１１は、可塑性の合成樹脂繊維であるポリエステル繊維で構成された不織布シートＡで構成されており、この不織布シートＡが、弾性基材Ｂとして機能する支持層１２のスポンジ層１３側とは反対側の面に接着される。 The non-woven fabric layer 11 is composed of a non-woven fabric sheet A composed of polyester fibers that are plastic synthetic resin fibers, and this non-woven fabric sheet A is the sponge layer 13 side of the support layer 12 functioning as the elastic base material B It is glued to the opposite side.
尚、本実施形態の洗浄具１０における各層、特に不織布シートＡと弾性基材Ｂとは、互いの境界面に接着剤を塗布して接着されているが、例えば熱融着等の別の接着方法により接着しても構わない。 In addition, although each layer in the cleaning tool 10 of the present embodiment, in particular, the nonwoven fabric sheet A and the elastic base material B, is adhered by applying an adhesive to the interface between each other, for example, another adhesion such as heat fusion You may adhere by a method.
以上が洗浄具１０の基本構成であるが、更に本実施形態の洗浄具１０は、優れた使用感と長寿命化を実現しつつ、不織布シートＡの表面の使用に伴う縮みや毛羽立ちを抑制するための特徴構成を有しており、以下にその詳細について説明する。 The above is the basic configuration of the cleaning tool 10. Furthermore, the cleaning tool 10 of the present embodiment suppresses shrinkage and fuzz associated with the use of the surface of the non-woven fabric sheet A while realizing excellent usability and long life. And the details thereof will be described below.
図３の不織布シートＡの断面写真において上面に位置する不織布シートＡの表面は、図４の写真にも示されているように、ポリエステル繊維の一部が溶融してなる溶融部Ｍが形成された溶融部形成面Ａｆとされている。このことで、被洗浄物に摺擦される洗浄面となる不織布シートＡの溶融部形成面Ａｆが、被洗浄物を洗浄する洗浄時において、比較的硬い溶融部Ｍが被洗浄物に摺擦されるので研磨力が向上する上に、上記溶融部Ｍにより繊維間が適度に結合されることで使用に伴う縮みや毛羽立ちが抑制されて長寿命化が図られている。 The surface of the nonwoven fabric sheet A located on the upper surface in the cross-sectional photograph of the nonwoven fabric sheet A in FIG. 3 is formed with a melted portion M in which a part of the polyester fibers is melted as shown in the photograph in FIG. It is set as the fusion zone formation face Af. As a result, the melted portion forming surface Af of the non-woven fabric sheet A, which becomes the cleaning surface to be rubbed against the object to be cleaned, rubs the relatively hard melted portion M on the object to be cleaned Therefore, the polishing force is improved, and the fibers are appropriately connected by the melting portion M, whereby shrinkage and fuzzing with use are suppressed and a long life is achieved.
一方、図３の不織布シートＡの断面写真において下面に位置する不織布シートＡの裏面は、図５の写真にも示されているように、上記のような溶融部Ｍが形成されていない溶融部非形成面Ａｂとされており、この溶融部非形成面Ａｂが弾性基材Ｂ（図２参照）に対して接着される。このことで、その溶融部非形成面Ａｂへの接着剤等の浸透が良好なものとなり、弾性基材Ｂへの接着が強力且つ均一なものとなる。従って、簡単な接着を施してその接着部の柔軟性が確保されながら、弾性基材Ｂに対する不織布シートＡの剥離が抑制されている。 On the other hand, the back surface of the nonwoven fabric sheet A located on the lower surface in the cross-sectional photograph of the nonwoven fabric sheet A of FIG. 3 is a molten portion where the above-mentioned fusion portion M is not formed as shown in the photograph of FIG. The non-forming surface Ab is bonded to the elastic base material B (see FIG. 2). By this, the penetration of the adhesive or the like to the molten-portion non-forming surface Ab becomes good, and the adhesion to the elastic base B becomes strong and uniform. Therefore, peeling of the nonwoven fabric sheet A with respect to the elastic base material B is suppressed, applying simple adhesion and ensuring the softness of the adhesion part.
このような溶融部形成面Ａｆ及び溶融部非形成面Ａｂは、弾性基材Ｂに接着される前の不織布シートＡに対して表面側から輻射熱を照射する輻射式加熱処理を施すことにより形成される。
以下、その輻射式加熱処理を含む不織布シートＡの製造方法について、図６に基づいて説明を加える。
Such a fused part forming surface Af and a fused part non-formed surface Ab are formed by performing a radiant heat treatment of irradiating radiant heat from the surface side to the nonwoven fabric sheet A before being bonded to the elastic base material B. Ru.
Hereinafter, the manufacturing method of the nonwoven fabric sheet A including the radiation type heat treatment will be described based on FIG.
先ず、ポリエステル繊維からなり乾式法又は湿式法等の公知の方法で製作されたウェブＷをニードルパンチ１１０で処理することで、ポリエステル繊維同士が緻密に交絡した状態の不織布シートＡ’が製造される。
尚、本実施形態において、詳細な図示は省略するが、このウェブＷは、カードで処理された厚さ約５ｍｍのポリエステル繊維製のスライバーを２８枚重ねたものであり、これをニードルパンチ１１０で処理することで、厚さ約２．７ｍｍ不織布シートＡ’が製造される。
First, the web W made of polyester fibers and manufactured by a known method such as a dry method or a wet method is treated with the needle punch 110 to produce a non-woven sheet A 'in a state in which the polyester fibers are densely entangled. .
In the present embodiment, although not shown in detail, the web W is a stack of 28 slivers of polyester fiber having a thickness of about 5 mm and treated with a card. By processing, about 2.7 mm in thickness non-woven sheet A 'is manufactured.
その不織布シートＡ’を搬送するコンベア１４０の上面側には、上記輻射式加熱処理を行うための輻射式加熱装置１２０が配置されており、この輻射式加熱装置１２０は、当該コンベア１４０で搬送される不織布シートＡ’の表裏面のうちの表面側に対して３ｃｍ〜４ｃｍ程度離間した位置から輻射熱を照射することが可能な状態で赤外線ヒータ１２０ａが設けられている。 A radiation type heating device 120 for performing the radiation type heat treatment is disposed on the upper surface side of the conveyor 140 which conveys the nonwoven fabric sheet A ′, and the radiation type heating device 120 is conveyed by the conveyor 140. The infrared heater 120a is provided in the state which can irradiate radiant heat from the position left | separated about 3 cm-4 cm with respect to the surface side among front and back of non-woven fabric sheet A '.
また、輻射式加熱装置１２０の下方を通過して表面側のみに輻射熱が照射された後の不織布シートＡは、当該輻射熱により溶融したポリエステル繊維が硬化する程度に除冷された上で、巻き取り装置１３０で巻き取られて、次の工程に搬送される。 In addition, the non-woven fabric sheet A after passing through the lower side of the radiant heating device 120 and being irradiated with radiant heat only on the surface side is cooled down to such an extent that the polyester fiber melted by the radiant heat is cured. It is taken up by the device 130 and conveyed to the next step.
このように輻射式加熱装置１２０の下方を通過後の不織布シートＡの表面は、ポリエステル繊維の一部が輻射熱により溶融した後に冷却され硬化してなる溶融部Ｍが形成された溶融部形成面Ａｆとなり、この溶融部形成面Ａｆが被洗浄物に摺擦される洗浄面として利用される。 Thus, the surface of the non-woven fabric sheet A after passing under the radiant heating device 120 is a fused part forming surface Af on which a fused part M is formed by melting and cooling part of the polyester fiber after radiant heat The molten portion forming surface Af is used as a cleaning surface to be rubbed against the object to be cleaned.
一方、輻射式加熱装置１２０の下方を通過後の不織布シートＡの裏面は、輻射式加熱装置１２０から表面側に照射された輻射熱の影響が少ないことから、ポリエステル繊維の溶融が防止されて、溶融部Ｍが形成されることなくポリエステル繊維が緻密に交絡した状態で維持された溶融部非形成面Ａｂとなり、この溶融部非形成面Ａｂが弾性基材Ｂに接着される接着面となる。 On the other hand, the back surface of the non-woven fabric sheet A after passing under the radiant heating device 120 is less affected by the radiant heat radiated from the radiant heating device 120 to the front side, so melting of the polyester fiber is prevented and melted. It becomes a fusion part non-formation surface Ab maintained in a state where polyester fibers are tightly intertwined without forming a part M, and this fusion part non-formation surface Ab becomes an adhesive surface to be adhered to the elastic base material B.
更に、溶融部非形成面Ａｂへの輻射熱の影響を好適に抑制しつつ、溶融部形成面Ａｆの縮みや毛羽立ち等の損傷を好適に抑制可能な程度に、溶融部形成面Ａｆに溶融部Ｍを分散形成するために、不織布シートＡの表面側に対し、好適な加熱温度条件及び加熱時間条件で輻射式加熱処理が施される。 Furthermore, the melting portion M is formed on the melting portion forming surface Af to such an extent that damage such as shrinkage and fuzzing of the melting portion forming surface Af can be suitably suppressed while suitably suppressing the influence of radiant heat on the melting portion non-forming surface Ab. In order to disperse and form, radiation heat treatment is applied to the surface side of the nonwoven fabric sheet A under suitable heating temperature conditions and heating time conditions.
具体的に、不織布シートＡ’の表面側の任意の位置が輻射式加熱装置１２０の下方を通過している間に輻射熱が照射される積算時間を加熱時間とし、その加熱時間が、１秒〜１５秒の範囲内、好ましくは８〜１０秒の範囲内に設定されるように、コンベア１４０の搬送速度が調整されている。尚、この加熱時間については、加熱後の不織布シートＡの溶融部非形成面Ａｂ及び溶融部形成面Ａｆの状態が所望の状態となるように適宜調整可能である。 Specifically, the integration time during which radiant heat is irradiated while an arbitrary position on the surface side of the nonwoven fabric sheet A ′ passes below the radiant heating device 120 is a heating time, and the heating time is 1 second to The transport speed of the conveyor 140 is adjusted to be set in the range of 15 seconds, preferably in the range of 8 to 10 seconds. In addition, about this heating time, it can adjust suitably so that the state of fusion part non-formation side Ab of nonwoven fabric sheet A after heating and fusion part formation side Af will be in a desired state.
更に、コンベア１４０の搬送速度を設定した上で、輻射式加熱装置１２０の下方を通過している間の不織布シートＡ’の表面の最高温度を加熱温度とし、その加熱温度がポリエステル製繊維の融点（２５５℃〜２６５℃程度）を超える３００℃〜５００℃の範囲内に設定されるように、輻射式加熱装置１２０の出力や不織布シートＡ’の表面からの距離が調整されている。具体的に、本実施形態において、この加熱温度は４００℃程度に設定されている。 Furthermore, after setting the transport speed of the conveyor 140, the maximum temperature of the surface of the nonwoven fabric sheet A 'while passing under the radiant heating device 120 is taken as the heating temperature, and the heating temperature is the melting point of the polyester fiber The output of the radiation-type heating device 120 and the distance from the surface of the nonwoven fabric sheet A ′ are adjusted so as to be set in the range of 300 ° C. to 500 ° C. exceeding (about 255 ° C. to 265 ° C.). Specifically, in the present embodiment, the heating temperature is set to about 400.degree.
そして、上記のような加熱条件で、厚さ約２．７ｍｍの不織布シートＡ’に対して輻射式加熱処理を施すと、その表面側のポリエステル繊維が溶融して収縮することで、加熱後の不織布シートＡの厚みは約２．０ｍｍに収縮する。これにより、溶融部形成面Ａｆには適当に溶融部Ｍが分散形成されて、ごわつきや透水性低下が抑制されながら、使用に伴う縮みや毛羽立ち等の損傷が好適に抑制されることになる。尚、この収縮幅は、０．１ｍｍ〜２．０ｍｍの範囲内、好ましくは０．３ｍｍ〜１．５ｍｍの範囲内、より好ましくは０．５ｍｍ〜１．０ｍｍの範囲内が望ましい。 Then, when the radiation type heat treatment is applied to the non-woven fabric sheet A ′ having a thickness of about 2.7 mm under the above heating conditions, the polyester fibers on the surface side thereof are melted and shrunk. The thickness of the nonwoven fabric sheet A shrinks to about 2.0 mm. As a result, the melt portion M is appropriately dispersed and formed on the melt portion forming surface Af, and while the stiffness and the decrease in permeability are suppressed, damage such as shrinkage and fuzzing with use is suitably suppressed. The contraction width is desirably in the range of 0.1 mm to 2.0 mm, preferably in the range of 0.3 mm to 1.5 mm, and more preferably in the range of 0.5 mm to 1.0 mm.
上記のように輻射式加熱装置１２０における加熱時間や加熱温度等の加熱条件が設定されていることで、加熱後の不織布シートＡにおいて、表面側は、ポリエステル繊維を適度に溶融させて繊維間を結合すると共にごわつきや透水性の低下が抑制されるのに適当な溶融部Ｍが形成された溶融部形成面Ａｆとなり、一方、裏面側は、そのような溶融部Ｍが形成されることなくポリエステル繊維が緻密に交絡した状態で維持された溶融部非形成面Ａｂとなる。
尚、このような輻射式加熱処理の各種条件は、不織布シートＡに対し、表面には溶融部Ｍを形成して溶融部形成面Ａｆとすると共に、裏面には溶融部Ｍの形成を防止して溶融部非形成面Ａｂとし得る範囲内において、適宜改変しても構わない。
By setting the heating conditions such as the heating time and heating temperature in the radiation type heating device 120 as described above, in the non-woven sheet A after heating, the surface side appropriately melts the polyester fibers so that the fibers are separated. It becomes fusion part formation surface Af in which fusion part M was formed in order to combine with and to suppress stiffness and a fall in water permeability, and on the other hand, the back side is polyester without such fusion part M being formed. It becomes the fusion part non-formation surface Ab which is maintained in a state in which the fibers are closely entangled.
In addition, various conditions of such radiation type heat treatment form the fusion zone M on the surface of the nonwoven fabric sheet A to form the fusion zone forming surface Af, and prevent the formation of the fusion zone M on the back side. In the range which can be set as the fusion part non-formation side Ab, it may change suitably.
図３の不織布シートＡの断面写真を参照すると、本実施形態の不織布シートＡにおいて、溶融部Ｍは、表面側の溶融部形成面Ａｆのみならず、それよりも若干内部側の境界面Ｘまでの深さ部分にも形成されていることが確認できる。
そして、溶融部形成層Ｌｘのごわつきや透水性低下を抑制すると共に、使用に伴う縮みや毛羽立ち等の損傷が好適に抑制する目的で、溶融部形成面Ａｆにおいて溶融部Ｍが形成された溶融部形成層（溶融部形成面Ａｆから境界面Ｘまでの層）Ｌｘの厚みは、０．０１ｍｍ〜０．２０ｍｍの範囲内、好ましくは０．０３ｍｍ〜０．１５ｍｍの範囲内、より好ましくは０．０５ｍｍ〜０．１０ｍｍの範囲内が望ましい。尚、本実施形態において、溶融部形成層Ｌｘの厚みは、０．０７ｍｍとされている。尚、この溶融部形成層Ｌｘの厚みは、不織布シートＡを構成するスライバー約１枚の厚みに相当する。
Referring to the cross-sectional photograph of the non-woven fabric sheet A in FIG. 3, in the non-woven fabric sheet A of this embodiment, the fusion zone M extends not only to the fusion-portion-formed surface Af on the front side but also to the boundary X on the inner side slightly It can be confirmed that it is formed also in the depth portion of
Then, the melting portion in which the melting portion M is formed on the melting portion forming surface Af is for the purpose of suppressing the stiffness and the permeability decrease of the melting portion forming layer Lx and suitably suppressing the damage such as shrinkage and fuzzing with use. The thickness of the formed layer (a layer from the melt portion formed surface Af to the boundary surface X) Lx is in the range of 0.01 mm to 0.20 mm, preferably in the range of 0.03 mm to 0.15 mm, more preferably 0. A range of 05 mm to 0.10 mm is desirable. In the present embodiment, the thickness of the molten portion forming layer Lx is 0.07 mm. The thickness of the molten portion forming layer Lx corresponds to the thickness of about one sliver constituting the nonwoven fabric sheet A.
このことから、本実施形態の洗浄具１０では不織布シートＡの厚みを２ｍｍとしたが、不織布シートＡの厚みが本実施形態のものの半分程度である１ｍｍ以上、好ましくは１．５ｍｍ以上であれば、不織布シートＡの裏面を溶融部Ｍが形成されていない溶融部非形成面Ａｂとすることができることが判る。 From this, in the cleaning tool 10 of this embodiment, the thickness of the non-woven fabric sheet A is 2 mm, but if the thickness of the non-woven fabric sheet A is about 1 mm or more, preferably 1.5 mm or more, which is about half that of this embodiment. And it turns out that the back surface of nonwoven fabric sheet A can be made into fusion part non-formation side Ab in which fusion part M is not formed.
また、このような不織布シートＡの厚みに関し、不織布シートＡの表面の使用に伴う縮みや毛羽立ちなどの損傷が抑制されていることで、不織布シートＡの厚みを、従来の５ｍｍ以上の分厚いものとする必要がなく、３ｍｍ以下、好ましくは２．５ｍｍ以下の比較的薄いものとすることができる。 In addition, regarding the thickness of such non-woven fabric sheet A, the non-woven fabric sheet A having a thickness of 5 mm or more, which is conventional, is suppressed by suppressing damage such as shrinkage and fuzzing with use of the surface of non-woven fabric sheet A It is not necessary to do this, and it can be made relatively thin such as 3 mm or less, preferably 2.5 mm or less.
尚、この不織布シートＡの厚みは、表面には溶融部Ｍを形成して溶融部形成面Ａｆとすると共に、裏面には溶融部Ｍの形成を防止して溶融部非形成面Ａｂとし得る範囲内において、適宜改変しても構わない。 In addition, the thickness of the nonwoven fabric sheet A is a range in which the molten portion M is formed on the surface to form the molten portion forming surface Af, and the formation of the molten portion M is prevented on the back surface to form the molten portion non-forming surface Ab. You may change suitably inside.
また、不織布シートＡの表面を、使用に伴う縮みや毛羽立ち等の損傷を抑制するために十分な溶融部Ｍが形成された溶融部形成面Ａｆとすると共に、不織布シートＡの裏面を、弾性基材Ｂへの接着性を確保する溶融部非形成面Ａｂとし得る範囲内で、上記境界面Ｘの位置を、例えば溶融部非形成面Ａｂ側に変位させるなどのように、適宜変更しても構わない。 Further, the surface of the non-woven fabric sheet A is a molten portion-forming surface Af on which the melting portion M is formed sufficiently to suppress damage such as shrinkage and fuzzing with use, and the back surface of the non-woven fabric sheet A is an elastic base Even if the position of the interface X is displaced to the side of the non-molten area forming surface Ab within the range where the non-molten area forming surface Ab secures the adhesion to the material B, for example, I do not care.
〔別実施形態〕
上記本実施形態では、洗浄具１０に支持層１２を設け、その支持層１２を弾性基材Ｂとして、当該弾性基材Ｂに不織布シートＡを接着した構成を説明したが、別に、図７に示すように、このような支持層１２を省略しても構わない。
[Another embodiment]
Although the support layer 12 is provided on the cleaning tool 10 and the support layer 12 is used as the elastic base material B in the above embodiment, the non-woven fabric sheet A is adhered to the elastic base material B. As shown, such a support layer 12 may be omitted.
即ち、図７に示す別実施形態の洗浄具２０は、一方面側から順に、可塑性の合成樹脂繊維であるポリエステル繊維で構成された不織布シートＡで構成された厚みが略２ｍｍの不織布層２１と、細かい連続気泡を有し柔軟なウレタンフォームで構成された厚みが略１７ｍｍのスポンジ層２２とが、互いに接着剤や熱融着により接着されて積層してなる２重構造を有する。 That is, the cleaning tool 20 of another embodiment shown in FIG. 7 includes, in order from one surface side, a non-woven fabric layer 21 having a thickness of about 2 mm and made of non-woven fabric sheet A made of polyester fibers which are plastic synthetic resin fibers. The sponge layer 22 having fine open cells and composed of a flexible urethane foam and having a thickness of about 17 mm has a double structure in which the sponge layer 22 is adhered and laminated to each other by an adhesive or heat fusion.
このような別実施形態の洗浄具２０では、不織布層２１のスポンジ層２２側とは反対側の面（図７における洗浄具２０の上面）と、スポンジ層２２の不織布層２１側とは反対側の面（図７における洗浄具２０の下面）とが、食器等の被洗浄物を洗浄する際に、当該被洗浄物に摺擦される洗浄面として機能する。 In the cleaning tool 20 of such another embodiment, the opposite side to the sponge layer 22 side of the non-woven fabric layer 21 (upper surface of the cleaning tool 20 in FIG. 7) and the opposite side to the non-woven fabric layer 21 side of the sponge layer 22 When the object (the lower surface of the cleaning tool 20 in FIG. 7) of the present invention is used to clean an object to be cleaned such as dishes, it functions as a cleaning surface to be rubbed against the object to be cleaned.
そして、不織布層２１を構成する不織布シートＡの表面は、溶融部Ｍが形成された溶融部形成面Ａｆ（図４参照）とされ、同不織布シートＡの裏面は、溶融部Ｍが形成されていない溶融部非形成面Ａｂ（図５参照）とされて、弾性基材Ｂとして機能するスポンジ層２２に接着剤や熱融着により接着されることになる。 The surface of the non-woven fabric sheet A constituting the non-woven fabric layer 21 is a melting portion forming surface Af (see FIG. 4) where the melting portion M is formed, and the back surface of the non-woven fabric sheet A is formed with the melting portion M. The non-melted portion non-forming surface Ab (see FIG. 5) is adhered to the sponge layer 22 functioning as the elastic base B by an adhesive or heat fusion.
１０ 洗浄具
２０ 洗浄具
１２０ 輻射式加熱装置
Ａ 不織布シート
Ａｂ 溶融部非形成面
Ａｆ 溶融部形成面
Ｂ 弾性基材
Ｍ 溶融部
DESCRIPTION OF SYMBOLS 10 Cleaning tool 20 Cleaning tool 120 Radiation type heating apparatus A Non-woven fabric sheet Ab Melt part non-formation surface Af Melt part formation surface B Elastic base material M Melt part
Claims (5)
前記不織布シートの表面が、前記合成樹脂繊維の一部が溶融してなる溶融部が形成された溶融部形成面とされていると共に、
前記不織布シートの裏面が、前記弾性基材に接着される溶融部非形成面とされており、
前記弾性基材に接着される前の不織布シートに対して表面側から輻射熱を照射する輻射式加熱処理により、前記溶融部形成面及び前記溶融部非形成面が形成されており、
前記輻射式加熱処理における前記不織布シートの加熱前に対する加熱後の厚みの収縮幅が０．１ｍｍ〜２．０ｍｍの範囲内に設定されて前記溶融部形成面において複数の前記溶融部が互いに分散して形成されている洗浄具。 A cleaning tool constructed by bonding a non-woven sheet composed of a plastic synthetic resin fiber to the outer surface of an elastic base material,
The surface of the non-woven fabric sheet is a molten portion forming surface on which a molten portion formed by melting a part of the synthetic resin fiber is formed,
The back surface of the non-woven fabric sheet is a non-melted surface to be bonded to the elastic base material ,
The fused portion forming surface and the fused portion non-formed surface are formed by radiation heat treatment in which radiant heat is irradiated from the surface side to the nonwoven fabric sheet before being bonded to the elastic base material,
The shrinkage width of the thickness after heating relative to that before heating of the non-woven fabric sheet in the radiation heat treatment is set within a range of 0.1 mm to 2.0 mm, and the plurality of melted portions are mutually dispersed on the melted portion forming surface Cleaning tool being formed .
前記輻射式加熱処理における加熱条件として、加熱温度が３００℃〜５００℃の範囲内に設定され、加熱時間が１秒〜１５秒の範囲内に設定されている請求項４に記載の洗浄具。 The non-woven sheet is made of polyester fibers,
The cleaning tool according to claim 4, wherein a heating temperature is set in a range of 300 ° C to 500 ° C and a heating time is set in a range of 1 second to 15 seconds as heating conditions in the radiation heat treatment.
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