阅读说明：本技术 纤维体成形方法、纤维体成形装置及薄片 (Method and apparatus for forming fibrous body and sheet ) 是由 青山哲也 若林繁美 横川忍 中井葉子 中沢政彦 于 2020-11-25 设计创作，主要内容包括：本申请提供一种能够成形出纸力不均较小的纤维体的纤维体成形方法、纤维体成形装置以及薄片。所述纤维体成形方法包括：向纤维的第一原料赋予使纤维与纤维结合的结合材料的工序；对被赋予了所述结合材料的所述第一原料进行解纤而形成解纤物的工序；使所述解纤物进行堆积的工序；对被堆积的所述解纤物进行加热的工序。(The present application provides a fibrous body forming method, a fibrous body forming apparatus, and a sheet, which can form a fibrous body with a small paper force unevenness. The method for forming a fibrous body comprises: a step of providing a first material of fibers with a bonding material for bonding the fibers to the fibers; a step of forming a defibrated material by defibrating the first raw material to which the bonding material is applied; a step of stacking the defibrinated material; and heating the deposited defibrinated object.)

1. A method of forming a fibrous body comprising:

a step of providing a first raw material containing fibers with a bonding material for bonding the fibers to the fibers;

a step of forming a defibrated material by defibrating the first raw material to which the bonding material is applied;

a step of stacking the defibrinated material;

and heating the deposited defibrinated object.

2. The method of forming a fibrous body according to claim 1,

in the step of applying the bonding material, the bonding material is applied to the surface of the first material.

3. The fiber body forming method according to claim 1 or 2,

in the step of forming the defibrinated object, the first raw material to which the bonding material is applied and the second raw material to which the bonding material is not applied are defibrinated.

4. A method of forming a fibrous body, comprising:

preparing a material including fibers and a bonding material for bonding the fibers to the fibers;

a step of defibrating the material to form a defibrated product;

a step of stacking the defibrinated material;

a step of heating the deposited defibrinated object,

in the step of preparing the material, the material including the binder in an amount of 6.0 mass% or more with respect to the fibers is prepared.

5. The method of forming a fibrous body according to claim 4,

in the step of preparing the material, the material includes a resin material made of the bonding material.

6. The method of forming a fibrous body according to claim 1 or 4,

the bonding material is a thermoplastic resin or a thermosetting resin,

the glass transition point of the bonding material is 45 ℃ or higher.

7. A fibrous body forming apparatus comprising:

an imparting unit that imparts a bonding material for bonding fibers to a first raw material containing fibers;

a defibration unit that defibrates the first material to which the bonding material is applied to form a defibrated product;

a deposition unit that deposits the defibrinated material;

and a heating unit that heats the deposited defibrinated material.

8. The fiber body forming apparatus according to claim 7,

the imparting section has a roller that applies the bonding material on the first raw material.

9. The fiber body forming apparatus according to claim 7,

the imparting section includes a sprayer for spraying the bonding material to the first raw material.

10. The fiber body forming apparatus according to any one of claims 7 to 9,

the defibering unit defibers the first material to which the bonding material is applied and a second material to which the bonding material is not applied.

11. The fiber body forming apparatus according to claim 7,

the bonding material is a thermoplastic resin or a thermosetting resin,

the glass transition point of the bonding material is 45 ℃ or higher.

12. A sheet, wherein,

comprises a fiber and a resin, and

the resin is contained at 6.0% by mass or more with respect to the fiber.

Technical Field

The present invention relates to a fibrous body forming method, a fibrous body forming apparatus, and a sheet.

Background

In order to achieve a reduction in size and energy saving, a fibrous body forming apparatus has been proposed which is realized in a dry manner without using water as much as possible. For example, patent document 1 describes a technique of enhancing paper strength by spraying moisture added with a paper strength enhancing agent such as starch and pva (polyvinyl alcohol) from a moisture sprayer to a deposit of deinked fibers deposited on a mesh belt in a paper recycling device realized by a dry method.

However, in patent document 1, when the deposit of fibers is conveyed by the mesh belt, the fibers may fly as paper dust from the mesh belt and clog the ejection port of the moisture sprayer. Therefore, it is difficult to spray the paper strength enhancer to the deposit with good uniformity, and the paper strength of the formed paper becomes uneven.

Patent document 1: japanese patent laid-open No. 2012 and 144826

Disclosure of Invention

One embodiment of a method for forming a fibrous body according to the present invention includes: a step of providing a first raw material containing fibers with a bonding material for bonding the fibers to the fibers; a step of forming a defibrated material by defibrating the first raw material to which the bonding material is applied; a step of stacking the defibrinated material; and heating the deposited defibrinated object.

In one embodiment of the method for forming a fibrous body, the bonding material may be applied to the surface of the first raw material in the step of applying the bonding material.

In one embodiment of the method for forming a fibrous body, in the step of forming the defibered product, the first raw material to which the binder is added and the second raw material to which the binder is not added may be subjected to defibering.

One embodiment of a method for forming a fibrous body according to the present invention includes: preparing a material including fibers and a bonding material for bonding the fibers to the fibers; a step of defibrating the material to form a defibrated product; a step of stacking the defibrinated material; and a step of heating the deposited defibrinated objects, wherein in the step of preparing the material, the material containing the bonding material in an amount of 6.0% by mass or more with respect to the fibers is prepared.

In one aspect of the method for forming a fibrous body, the material may include a resin material made of the binder in the step of preparing the material.

In one embodiment of the fiber body molding method, the bonding material may be a thermoplastic resin or a thermosetting resin, and the glass transition point of the bonding material may be 45 ℃.

One embodiment of a fiber forming apparatus according to the present invention includes: an imparting unit that imparts a bonding material for bonding fibers to a first raw material containing fibers; a defibration unit that defibrates the first material to which the bonding material is applied to form a defibrated product; a deposition unit that deposits the defibrinated material; and a heating unit that heats the deposited defibrinated material.

In one aspect of the fibrous body forming apparatus, the applying section may include a roller that applies the bonding material to the first raw material.

In one aspect of the fiber body forming method, the applying portion may have a nozzle that ejects the bonding material to the first raw material.

In one aspect of the fiber body forming method, the defibering unit may defiber the first material to which the bonding material is applied and a second material to which the bonding material is not applied.

In one embodiment of the fiber body molding method, the bonding material may be a thermoplastic resin or a thermosetting resin, and the glass transition point of the bonding material may be 45 ℃.

One embodiment of the sheet according to the present invention may include fibers and a resin, and the resin may be contained in an amount of 6.0% by mass or more with respect to the fibers.

Drawings

Fig. 1 is a schematic view of a fiber forming apparatus according to the present embodiment.

Fig. 2 is a flowchart for explaining the fiber forming method according to the present embodiment.

Fig. 3 is a flowchart for explaining the fiber forming method according to the present embodiment.

Fig. 4 is a flowchart for explaining the fiber forming method according to the present embodiment.

Fig. 5 is a flowchart for explaining a fiber body forming method according to a modification of the present embodiment.

Fig. 6 is a flowchart for explaining a fiber body forming method according to a modification of the present embodiment.

Fig. 7 is a diagram for explaining a sheet used for evaluation.

Detailed Description

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The embodiments described below are not intended to unduly limit the contents of the present invention recited in the patent claims. All the structures described below are not necessarily essential to the present invention.

1. Fibrous body forming device

1.1. Integral structure

First, a fiber forming apparatus according to the present embodiment will be described with reference to the drawings. Fig. 1 is a schematic view of a fiber forming apparatus 100 according to the present embodiment.

As shown in fig. 1, the fibrous body forming apparatus 100 includes, for example, a supply section 10, a rough crushing section 12, a defibration section 20, a screening section 40, a first web forming section 45, a rotating body 49, a stacking section 60, a second web forming section 70, a sheet forming section 80, a cutting section 90, and an applying section 110.

The supply unit 10 supplies the raw material to the coarse crushing unit 12. The supply unit 10 is, for example, an automatic charging unit for continuously charging the raw material into the coarse crushing unit 12. The raw material supplied through the supply portion 10 includes, for example, fibers such as waste paper or pulp sheets.

The applying unit 110 applies a bonding material for bonding the fibers to the raw material supplied from the supplying unit 10. Details of the imparting portion 110 will be described later.

The rough crushing section 12 cuts the raw material supplied through the supply section 10 in an atmosphere or the like to form chips. The shape and size of the chips are, for example, chips in a few cm square. In the illustrated example, the rough crush portion 12 has a rough crush blade 14, and can cut the charged raw material by the rough crush blade 14. As the rough crush portion 12, a shredder is used, for example. The raw material cut by the rough crushing section 12 is received by the hopper 1 and then transferred to the defibration section 20 through the pipe 2.

The defibering unit 20 performs defibering of the raw material cut by the rough crushing unit 12. Here, "defibering" means that a raw material obtained by bonding a plurality of fibers is defibered into fibers one by one. The defibration section 20 also has a function of separating substances such as resin particles, ink, toner, and a bleeding inhibitor, which are attached to the raw material, from the fibers.

The substance passing through the defibration section 20 is referred to as "defiberized substance". The "defibrinated product" may include, in addition to the defibrinated product fiber, resin particles separated from the fiber during defibrination, coloring materials such as ink and toner, a barrier material, and additives such as a paper strength enhancer. The shape of the defibrinated object after being disassembled is rope-shaped. The defibered product may be present in a state of not being entangled with other defibered fibers, that is, in a state of being independent of each other, or may be present in a state of being entangled with other defibered products in a lump, that is, in a state of being formed into a lump.

The defibration unit 20 performs defibration in a dry manner. Here, a method of performing a treatment such as defibration in a gas such as air, not in a liquid, is referred to as a dry method. As the defibration section 20, for example, an impeller mill is used. The defibration section 20 has a function of generating a gas flow such as sucking the raw material and discharging the defibrated material. In this way, the defibration section 20 sucks the raw material from the inlet 22 together with the air flow by the air flow generated by itself to perform the defibration process, and conveys the defibrated material to the outlet 24. The defibered product having passed through the defibering unit 20 is transferred to the screen unit 40 through the pipe 3. The air flow for conveying the defibered material from the defibering unit 20 to the screening unit 40 may be the air flow generated by the defibering unit 20, or may be an air flow generating device such as a blower, and the air flow may be used.

The screening section 40 introduces the defibered material, which has been defibered by the defibering section 20, from the introduction port 42, and screens the material according to the length of the fiber. The screening portion 40 includes a drum portion 41 and a housing portion 43 that houses the drum portion 41. As the drum part 41, for example, a sieve is used. The drum portion 41 has a net, and can distinguish a first sorted material in which fibers or particles smaller than the mesh size of the net, that is, a material passing through the net, from a second sorted material in which fibers, undeveloped pieces, or clumps larger than the mesh size of the net, that is, a material not passing through the net. For example, the first sorted material is transferred to the stacking unit 60 through the pipe 7. The second screened material is returned from the discharge port 44 to the defibration section 20 via the tube 8. Specifically, the drum portion 41 is a cylindrical screen that is rotationally driven by a motor. As the net of the drum portion 41, for example, a wire mesh, a porous metal net obtained by drawing a metal plate provided with a slit, and a punched metal plate obtained by forming a hole in a metal plate by a punching machine or the like are used.

The first web forming section 45 conveys the first screen passed through the screen section 40 to the tube 7. The first web forming section 45 includes a mesh belt 46, a tension roller 47, and a suction mechanism 48.

The suction mechanism 48 can suck the first screen material dispersed in the air through the opening of the screen section 40 onto the mesh belt 46. The first screen is stacked on the moving mesh belt 46, thereby forming the web V. The basic structures of the mesh belt 46, the tension roller 47, and the suction mechanism 48 are the same as those of the mesh belt 72, the tension roller 74, and the suction mechanism 76 of the second web forming portion 70 described below.

The web V passes through the screen section 40 and the first web forming section 45 to be formed into a state rich in air and soft and fluffy. The web V stacked on the mesh belt 46 is thrown into the tube 7 and conveyed to the stacking portion 60.

The rotating body 49 can cut the web V. In the illustrated example, the rotating body 49 has a base portion 49a and a protrusion portion 49b protruding from the base portion 49 a. The projection 49b has a plate-like shape, for example. In the illustrated example, four protrusions 49b are provided, and four protrusions 49b are provided at equal intervals. The base portion 49a is rotated in the direction R, so that the projection portion 49b can be rotated about the base portion 49 a. By cutting the web V with the rotating body 49, for example, the variation in the amount of the defibrated material per unit time supplied to the accumulating portion 60 can be reduced.

The rotator 49 is provided in the vicinity of the first web forming portion 45. In the illustrated example, the rotating body 49 is provided in the vicinity of the tension roller 47a located on the downstream side in the path of the web V. The rotating body 49 is provided at a position where the protrusions 49b can contact the web V and are not in contact with the web 46 on which the web V is stacked. This can suppress the wear of the mesh belt 46 due to the projection 49 b. The shortest distance between the projection 49b and the mesh belt 46 is, for example, 0.05mm or more and 0.5mm or less. This is the distance that the web sheet V can be cut by the web tape 46 without being damaged.

The stacking section 60 introduces the first sorted material from the introduction port 62, unwinds the entangled object, and drops the object while dispersing the object in the air. The accumulation section 60 can accumulate the first screen on the second web forming section 70 with good uniformity.

The stacking portion 60 includes a roller portion 61 and a housing portion 63 for housing the roller portion 61. A rotating cylindrical screen is used as the drum portion 61. The drum portion 61 has a net, and drops fibers or particles smaller than the mesh size of the net. The structure of the drum portion 61 is, for example, the same as that of the drum portion 41.

The "screen" of the drum portion 61 may not have a function of screening a specific object. That is, the "screen" used as the drum part 61 means a member having a net, and the drum part 61 may drop all the defibrinated material introduced into the drum part 61.

The second web forming portion 70 stacks the passage passed through the stacking portion 60, thereby forming the web W. The second web forming section 70 has, for example, a mesh belt 72, a tension roller 74, a suction mechanism 76.

The mesh belt 72 moves while accumulating the passing objects passing through the opening of the accumulation section 60. The mesh belt 72 is stretched by the stretching roller 74, and air passes through the mesh belt with difficulty. The mesh belt 72 is rotated and moved by the tension roller 74. The web W is formed on the mesh belt 72 by continuously accumulating the passes passing through the accumulation section 60 while the mesh belt 72 is continuously moving.

The suction mechanism 76 is disposed below the mesh belt 72. The suction mechanism 76 is capable of generating a downward-directed airflow. The fluff dispersed in the air by the accumulating section 60 is sucked onto the mesh belt 72 by the suction mechanism 76. This can increase the discharge speed of the discharge from the stacking unit 60. Further, the suction mechanism 76 can form a down-flow on the falling path of the defibrated material, and prevent the defibrated material or the additive from being entangled during the falling process.

As described above, by passing through the stacking portion 60 and the second web forming portion 70, the web W is formed in a state rich in air and soft and fluffy. The web W stacked on the mesh belt 72 is conveyed toward the sheet forming portion 80.

The sheet forming section 80 applies pressure and heat to the web W stacked on the mesh belt 72, thereby forming the sheet S. In the sheet forming portion 80, the plurality of fibers in the mixture can be bonded to each other via the bonding material by applying heat to the mixture of the defibrates and the bonding material mixed together in the web W.

The sheet forming section 80 includes a pressing section 82 that presses the web W, and a heating section 84 that heats the web W pressed by the pressing section 82. The pressing portion 82 is constituted by a pair of reduction rollers 85, and applies pressure to the web W. The web W is made smaller in thickness by being pressed, and the bulk density of the web W is increased. As the heating section 84, for example, a heating roller, a hot press molding machine, a hot plate, a warm air blower, an infrared heater, and a flash fixing device are used. In the illustrated example, the heating unit 84 includes a pair of heating rollers 86. By using the heating section 84 as the heating roller 86, the sheet S can be formed while continuously conveying the web W, as compared with the case where the heating section 84 is configured as a plate-like pressing device. The reduction roll 85 and the heating roll 86 are disposed such that their rotation axes are parallel to each other, for example. Here, the calender rolls 85 can apply a higher pressure to the web W than the pressure applied to the web W by the heating roll 86. The number of the reduction rolls 85 and the heating rolls 86 is not particularly limited.

The cutting section 90 cuts the sheet S formed by the sheet forming section 80. In the illustrated example, the cutting section 90 has a first cutting section 92 that cuts the sheet S in a direction intersecting the conveying direction of the sheet S, and a second cutting section 94 that cuts the sheet S in a direction parallel to the conveying direction. The second cutting portion 94 cuts the sheet S passing through the first cutting portion 92, for example.

In this way, a single sheet S of a predetermined size is formed. The cut sheet S is discharged to the discharge section 96.

1.2. Imparting unit

The imparting unit 110 imparts a bonding material for bonding fibers to a raw material containing fibers. The raw material containing fibers is, for example, waste paper. In the illustrated example, the imparting portion 110 imparts the bonding material to the raw material that is supplied from the supply portion 10 and before being coarsely crushed by the coarse crushing portion 12. The length of the fibers contained in the raw material is, for example, 0.6mm to 3.0mm as the length average fiber length. The length average Fiber length of the fibers can be measured based on "ISO 16065-2: 2007" using "Fiber Tester CODE 912" manufactured by L & W.

The applying section 110 may apply a liquid containing a binding material to the surface of the raw material. The applying section 110 may have a roller for applying the bonding material to the raw material. Alternatively, the applying section 110 may include a sprayer for spraying the binding material to the raw material. Alternatively, the applying unit 110 may be an ink jet head that ejects the bonding material to the raw material.

The binding material applied by the applying portion 110 may be dissolved in a liquid or may be dispersed in a liquid. The liquid is preferably an emulsion in which the binding material is dispersed, preferably in nano-size. In the case of an emulsion, the viscosity of the liquid is preferably lowered, and the liquid can penetrate into the inside of the fibrous body to further improve the bonding force. The nano-size is preferable because clogging of the nozzle, which occurs in, for example, a nebulizer or an ink jet head, is easily avoided.

The bonding material applied by the applying unit 110 is, for example, a thermoplastic resin or a thermosetting resin.

Examples of the thermoplastic resin include AS (acrylonitrile styrene) resin, ABS (acrylonitrile butadiene styrene) resin, polypropylene, polyethylene, polyvinyl chloride, polystyrene, acrylic resin, polyester resin, polyethylene terephthalate, polyphenylene ether, polybutylene terephthalate, nylon, polyamide, polycarbonate, polyacetal, polyphenylene sulfide, and polyether ether ketone. These resins may be used alone or as appropriate in combination. Further, copolymerization and modification can be performed, and examples of such a resin system include styrene-based resins, acrylic resins, styrene-acrylic copolymerized resins, olefin-based resins, vinyl chloride-based resins, polyester-based resins, polyamide-based resins, polyurethane-based resins, polyvinyl alcohol-based resins, vinyl ether-based resins, N-vinyl-based resins, styrene-butadiene-based resins, and the like.

Examples of the thermosetting resin include phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, and thermosetting polyimide resins.

The higher the glass transition point of the thermoplastic resin and the thermosetting resin, the better from the viewpoint of high temperature resistance, but there is an appropriate range in view of various circumstances such as energy saving in production. The glass transition point is appropriately selected depending on, for example, the thickness of the sheet S or the temperature in the case where heat treatment is performed. The glass transition temperature is preferably 45 ℃ or higher, more preferably 50 ℃ or higher, and further preferably 60 ℃. Further, the glass transition point is preferably 130 ℃ and more preferably 100 ℃. If the glass transition point is 45 ℃ or higher, softening of the bonding material at high temperature is suppressed, and a sheet S with high paper strength is obtained. Further, if the glass transition point is 60 ℃ or higher, when the raw material to which the bonding material is applied is defibered in the defibering portion 20, the bonding material can be prevented from softening by the heat of the defibering portion 20 and adhering to the defibering portion 20. The bonding material is preferably a resin having a melting point equal to or higher than the temperature of the defibration portion 20. The melting point of the bonding material is preferably 220 ℃ or lower.

The applying section 110 applies the bonding material to the raw material so that the bonding material is 6.0% by mass or more, preferably 9.0% by mass or more, with respect to the fibers included in the raw material. If the binder is 6.0% by mass or more, the paper strength of the sheet S can be improved. In the sheet S, for example, the binder is contained at 6.0% by mass or more with respect to the fibers.

In addition to the bonding material, the applying portion 110 may apply an additive such as a flame retardant, a perfume, an antistatic agent, and an ultraviolet absorber to the raw material. If such an additive is applied together with the binder by the applying section 110, it is not necessary to separately provide an ink cartridge for applying the additive, and therefore, the device can be downsized. The imparting section 110 does not impart a color material to the raw material.

Although not shown, the applying unit 110 may apply the bonding material to the raw material coarsely crushed by the coarse crushing unit 12 before the fiber is crushed by the fiber crushing unit 20. In this case, the applying portion 110 is preferably a sprayer. When the binding material is applied to the raw material by a roller, it is preferable that the applying portion 110 applies the binding material to the raw material before the coarse crushing by the coarse crushing portion 12.

The applying unit 110 may not be a liquid containing a binding material, and may apply a powder as a binding material to the raw material. However, when the binder is a powder, the binder is preferably fixed to the raw material by heat in order to prevent the binder from falling from the raw material. For example, the binder may be fed into the defibration section 20 and fixed to the raw material by the heat of the defibration section 20.

1.3. Effect

The fibrous body forming apparatus 100 has the following effects, for example.

The fiber forming apparatus 100 includes: an applying unit 110 that applies a bonding material for bonding fibers to a raw material containing fibers; a defibration unit 20 that defibrates a raw material to which a binding material is applied to form a defibrated product; a deposition part 60 for depositing the defibrated material, and a heating part 84 for heating the deposited defibrated material. Therefore, in the fibrous body forming apparatus 100, since the bonding material can be not applied to the defibrinated object accumulated by the accumulation portion, the fibers are unlikely to fly from the mesh belt as paper dust and to clog the ejection port of the application portion. Therefore, the sheet S (fibrous body) with less paper force variation can be formed.

In the fibrous body forming apparatus 100, the defibration section 20 has a function of mixing the raw material and the binder. Therefore, even if the binding material is biased at the time point when the binding material is applied to the raw material, the biasing of the binding material can be alleviated by the defibering portion 20, and a sheet S with less paper force variation can be formed. Therefore, even if a part of the ejection port of the applying portion 110 is blocked, the bonding material can be applied without taking care of the unevenness of the bonding material. Further, since it is not necessary to separately provide a mixing section for mixing the raw material and the binding material, the apparatus can be miniaturized.

In the fibrous body forming apparatus 100, the applying section 110 may include a roller for applying the bonding material to the raw material. Therefore, in the fibrous body forming apparatus 100, the binder can be uniformly applied to the raw material. The roller can be easily applied regardless of the viscosity of the liquid containing the binding material, as compared to an atomizer or an ink-jet head.

In the fiber forming apparatus 100, the bonding material may be a thermoplastic resin or a thermosetting resin, and the glass transition point of the bonding material may be 45 ℃ or higher. Therefore, in the fibrous body forming apparatus 100, the bonding material can be easily melted by the heating section 84.

2. Method for forming fibrous body

Next, a method for forming a fibrous body according to the present embodiment will be described with reference to the drawings. Fig. 2 is a flowchart for explaining the fiber forming method according to the present embodiment.

The fiber forming method according to the present embodiment is performed using, for example, the fiber forming apparatus 100 described above. The fibrous body forming method according to the present embodiment may be performed by using an apparatus other than the fibrous body forming apparatus 100.

As shown in fig. 2, the method for forming a fibrous body according to the present embodiment includes: a bonding material imparting step (step S11) of imparting a bonding material for bonding fibers to a raw material containing fibers; a defibering step (step S12) of defibering the raw material to which the binding material is applied to form a defibered product; a deposition step (step S13) for depositing the defibrated material; and a heating step of heating the accumulated defibrinated objects (step S14).

The bonding material applying step (step S11) is performed, for example, using the applying unit 110 of the fibrous body forming apparatus 100.

The defibering step (step S12) is performed using, for example, the defibering section 20 of the fibrous body forming apparatus 100.

The deposition step (step S13) is performed using, for example, the deposition unit 60 of the fibrous body forming apparatus 100.

The heating step (step S14) is performed using, for example, the heating section 84 of the fibrous body forming apparatus 100.

The fibrous body forming method according to the present embodiment may include, in addition to the above-described steps, the steps described in the above-described "fibrous body forming apparatus 1", such as a step of pressing the web W by the pressing section 82.

In the fibrous body forming method according to the present embodiment, the sheet S having small paper force unevenness can be formed as described in the above-mentioned "fibrous body forming apparatus 1".

In the example of fig. 2, the raw material to which the binding material is applied is defibered in the binding material applying step in the defibering step, but as shown in fig. 3, the raw material to which the binding material is applied (first raw material) and the sheet S molded through the heating step may be defibered in the defibering step. In the example shown in fig. 3, the sheet S is a raw material (second raw material) to which no bonding material is given. The defibration section 20 may perform defibration of the first material and the second material. Here, the "raw material to which no bonding material is applied" refers to a material to which no bonding material is applied in the bonding material application step after being formed into a sheet through the heating step.

As shown in fig. 4, in the defibering step, the raw material to which the bonding material is applied in the bonding material applying step and the sheet S to which the bonding material is applied in the bonding material applying step after being molded in the heating step may be defibered.

3. Modification of fiber body forming method

Next, a method for forming a fibrous body according to a modification of the present embodiment will be described with reference to the drawings. Fig. 5 is a flowchart for explaining a fiber body forming method according to a modification of the present embodiment. Hereinafter, in the fiber forming method according to the modified example of the present embodiment, points different from the above-described example of the fiber forming method according to the present embodiment will be described, and description of the same points will be omitted.

As shown in fig. 2, the fiber body forming method according to the present embodiment includes a bonding material applying step (step S11). On the other hand, as shown in fig. 5, the fibrous body molding method according to the modification of the present embodiment includes a material preparation step (step S21).

As shown in fig. 5, the method for forming a fibrous body according to the modification of the present embodiment includes: a material preparation step (step S21) for preparing a material including fibers and a bonding material for bonding the fibers to the fibers; a defibering step (step S22) of defibering the material to form a defibered product; a deposition step (step S23) for depositing the defibrated material; and a heating step of heating the accumulated defibrinated objects (step S24).

In the material preparation process (step S21), the material includes, for example, waste paper and resin composed of a binding material. The resin material may be composed of a thermoplastic resin, a thermosetting resin, a thermoplastic resin and a thermosetting resin.

The shape of the resin material is not particularly limited, and may be, for example, a sheet (single sheet), a sheet finely cut into individual pieces, a dice, or a ball. The resin material is preferably a sheet-like resin sheet. If the resin article is a resin sheet, the resin article can be supplied by, for example, providing a sheet-feeding stacker for supplying the resin article to the supply portion 10 of the fibrous body forming apparatus 100. In the material preparation step, resin sheets of the same number as the waste paper may be prepared. When the fiber forming method according to the modification of the present embodiment is performed using the fiber forming apparatus 100, the applying unit 110 may not be driven. Alternatively, the providing unit 110 may not be provided.

In the material preparation step, a material containing a binder in an amount of 6.0% by mass or more with respect to the fibers is prepared. For example, when waste paper or resinous material is prepared as a material, if the mass of the fibers contained in the waste paper is 100, the total mass of the resin contained in the waste paper and the mass of the resinous material is 6.0% or more by mass. In the material preparation step, it is preferable to prepare a material containing 9.0% by mass or more of the binder with respect to the fibers. If the binder is contained in an amount of 6.0 mass% or more with respect to the fibers, the sheet S having a high paper force can be formed.

The defibering process (step S22) is the same as the defibering process (step S12). The deposition step (step S23) is the same as the deposition step (step S13). The heating step (step S24) is the same as the heating step (step S14) described above.

The fiber body forming method according to the modification of the present embodiment has the following effects, for example.

In the fibrous body forming method according to the modification of the present embodiment, the sheet S having small paper force variation can be formed in the same manner as the fibrous body forming method according to the present embodiment.

In the fibrous body forming method according to the modification of the present embodiment, the applying step is not performed as in the fibrous body forming method according to the present embodiment described above, and therefore, for example, the applying unit 110 of the fibrous body forming apparatus 100 can be omitted. Therefore, the fiber forming apparatus can be downsized.

In the fibrous body forming method according to the modification of the present embodiment, in the material preparation step, the material may include a resin material made of a binder. Therefore, since it is not necessary to apply a liquid containing a binding material, a drying step after applying the liquid can be omitted.

In addition, the sheet-like resin material is easy to stock and manage, and the work efficiency is good. The resin material is not limited by the powder characteristics such as pulverization and fluidity, dispersibility, ejection property, storage stability, and phase solvent, and the type of resin can be selected.

In addition, for resin materials made of resins having different glass transition points, resin materials to which a flame retardant, an antistatic agent, an ultraviolet absorber, a perfume, and the like are added, and the like, a plurality of different kinds of functional agents can be added to the fibers as the resin materials according to the purpose, and customization of functions is easy.

In the fibrous body forming method according to the modification of the present embodiment, if a material in which the bonding material is contained in an amount of 6.0% by mass or more with respect to the fibers can be prepared in the material preparation step, as shown in fig. 6, a sheet S formed through a heating step may be prepared as the material in addition to the waste paper and the resin material.

In the fibrous body forming method according to the modification of the present embodiment, if a material containing 6.0% by mass or more of the binder to the fibers can be prepared in the material preparation step, waste paper and the sheet S may be prepared as the material without preparing a resin material.

4. Examples and comparative examples

4.1. Preparation of samples

4.1.1. Example 1

An ink jet printer "EW-M770T" manufactured by Seiko Epson corporation was used to apply a liquid to a recycled paper "G80" (grammage 64G/cm)²) The above raw materials. The composition of the liquid is as follows.

TABLE 1

Composition of liquid	Mass%
		Polyurethane	15
PG	10
		E1010	1
Water (W)	Residual amount of
		Total of	100

Further, "Super flex 130" manufactured by first Industrial pharmaceutical Co., Ltd was used as the polyurethane. Polyurethanes are the binding materials that bind the fibers to one another. In the table, "PG" is propylene glycol, and "E1010" is OLFINE E1010 manufactured by Nissan chemical industries, Ltd.

Next, the raw material coated with the liquid was used in a paper machine "PaperLab A8000" made by Seiko Epson corporation to prepare a paper having a grammage of 70g/m²The sheet of (1). The content of the binder relative to the fibers of the sheet was 9.0% by mass. In "PaperLab a 8000", no binding material is given to the raw material. That is, in example 1, the liquid containing the binding material was applied and then defibration was performed.

4.1.2. Comparative example 1

"G80" as a raw material was used to prepare a web in "PaperLab A8000" without adding a binder. Next, the web was coated with the liquid shown in table 1 using "EW-M770T", and then the web was pressurized by a pressurizing unit and then heated by a heating unit to produce a grammage of 70g/M²The sheet S of (1). That is, in comparative example 1, after the defibration was performed, a liquid-containing bonding material was applied.

4.2. Evaluation method

4.2.1 first evaluation

The printing of "EW-M770T" was performed in a state where four dots were omitted from the nozzle. As shown in fig. 7, in comparative example 1, a missing part N formed by dot omission was confirmed in the produced sheet. In example 1, since the defibration was performed after the printing, no missing portion was observed in the produced sheet. The produced sheet was cut into a rectangle having a width of 20mm in the short side direction. In comparative example 1, the sheet was cut so as to include the missing portion N. In fig. 7, the cut sheet of comparative example 1 is shown by a broken line. The sheet was measured for specific tensile strength in the longitudinal direction by the method described in JIS P8113: 2006 using a tensile tester "AGS-X-500N" manufactured by Shimadzu corporation.

The evaluation criteria for specific tensile strength are as follows.

A is a specific tensile strength of 20Nm/g or more

B specific tensile strength of less than 20Nm/g

4.2.2 second evaluation

The printing of "EW-M770T" was repeated in a state where four dots were omitted from the nozzle. Further, the application unevenness of the liquid was confirmed by visual confirmation.

The evaluation criteria for coating unevenness are as follows.

A, coating unevenness was not observed visually.

B, uneven coating can be avoided.

4.3 evaluation results

Table 2 shows the evaluation results of the specific tensile strength and coating unevenness.

TABLE 2

	Example 1	Comparative example 1
			Evaluation 1 (specific tensile Strength)	A(29Nm/g)	B(19Nm/g)
Evaluation 2 (uneven coating)	A	B

In example 1, since the defibration was performed after the printing, a missing portion formed by missing dots was not generated in the produced sheet. Therefore, as shown in table 2, example 1 has higher specific tensile strength than comparative example 1. In addition, in example 1, since the defibration was performed after the printing, even if the printing was repeated in a state where the dots were omitted, the bonding material was uniformized, and the coating unevenness was not confirmed. As is clear from this evaluation, by applying a liquid containing a binder before defibration, a sheet having a small paper force unevenness can be formed.

The present invention may omit a part of the configuration within the scope of having the features and effects described in the present application, and may be combined with each embodiment and the modification.

The present invention is not limited to the above-described embodiments, and various modifications can be further implemented. For example, the present invention includes substantially the same structures as those described in the embodiments. The substantially same structure means, for example, a structure having the same function, method, and result, or a structure having the same purpose and effect. The present invention includes a structure in which the nonessential portions of the structures described in the embodiments are replaced. The present invention includes a structure that achieves the same operational effects or the same objects as the structures described in the embodiments. The present invention includes a configuration in which a known technique is added to the configurations described in the embodiments.

Description of the symbols

1 … hopper; 2. 3, 7, 8 … tubes; 10 … supply part; 12 … coarse crushing part; 14 … coarse crushing blade; 20 … defibering part; 22 … introduction port; 24 … discharge ports; 40 … screening part; 41 … a roller portion; 42 … introduction port; 43 … housing portion; 44 … discharge port; 45 … a first web forming portion; 46 … mesh belt; 47; 47a … tension roller; 48 … suction mechanism; 49 … a rotating body; 49a … base; 49b … projection; 60 … stacking part; 61 … roller part; 62 … introduction port; 63 … housing portion; 70 … second web forming portion; 72 … mesh belt; 74 … tension roller; 76 … suction mechanism; 80 … sheet forming part; 82 … pressure part; 84 … heating section; 85 … calender rolls; 86 … heated roller; a 90 … cut-off portion; 92 … a first cut-out; 94 … second cut-out; 96 … discharge; 100 … a fiber body forming device; 110 … imparting portion.