JP2013174026A - Method and apparatus for producing fiber assembly - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method capable of producing a fiber assembly in which the amount of fibers having a small fiber diameter is uniform, and an apparatus for producing the same.
SOLUTION: The method for producing a fiber assembly of the present invention crosses the moving direction of a liquid pool with fibers formed by applying a gas and / or an electric field to a liquid pool of a resin liquid that moves by its own weight. It is the method of collecting with the collector which moves to the direction to do. The fiber assembly manufacturing apparatus can form a liquid pool of a resin liquid that moves by its own weight, and a spinning apparatus that can form fibers by applying a gas and / or an electric field to the resin liquid, and a liquid pool And a collecting body capable of collecting the fibers by moving in a direction crossing the moving direction.
[Selection] Figure 2

Description

  The present invention relates to a method for manufacturing a fiber assembly and a manufacturing apparatus therefor.

  If the fiber diameter of the fiber constituting the fiber aggregate, such as a fiber aggregate, is small, it has excellent performance such as separation performance, liquid retention performance, wiping performance, concealment performance, insulation performance, or flexibility. The fiber diameter of the fibers constituting the aggregate is preferably small.

  As an apparatus for producing such a fiber assembly composed of fibers having a small fiber diameter, as shown in FIG. 7, “the apparatus for forming a non-woven mat of nanofibers by using a compressed gas flow is provided with parallel intervals. And first (112), second (122) and third (132) members, each having a supply end (114, 124, 134) and an opposing outlet end (116, 126, 136). The second member (122) is adjacent to the first member (112) The outlet end (126) of the second member (122) extends beyond the outlet end (116) of the first member (112). The first (112) and second (122) members define a first supply slit (118), and the third member (132) is opposite the second member (122) of the first member (112). And located adjacent to the first member (112). 112) and the third (132) member define a first gas slit (138) and the outlet ends (116, 126, 136) of the first (112), second (122) and third (132) members. ) Defines a gas jet space (120), including a method of forming a nonwoven mat of nanofibers by using a compressed gas stream "(Patent Document 1). However, in this apparatus, since the flat plate-like first, second, and third members are provided in parallel, the sheet-like compressed gas acts on the sheet-like spinning solution, so that the fiber shape However, even if it was made into a fiber shape, only thick fibers could be formed.

As an apparatus that can solve such a problem, the applicant of the present application, as shown in FIG. 8, “at _{least one} liquid discharge part (El ₁ , El ₂ , El ₃ ... The following conditions include one or more gas discharge portions (Eg) that are located upstream of any liquid discharge portion (El ₁ , El ₂ , El ₃ ...) And extend linearly and can discharge gas. (1) having liquid columnar hollow portions (Hl ₁ , Hl ₂ , Hl ₃ ...) Whose ends are liquid discharge units (El ₁ , El ₂ , El ₃ ...), ( 2) It has gas columnar hollow portions (Hl ₁ , Hl ₂ , Hl ₃ ...) Whose ends are gas discharge portions (Eg), (3) Liquid columnar hollow portions (Hl ₁ , Hl ₂ , Hl ₃₎ ...) extended liquid virtual columnar portion _{(Hvl 1, Hvl 2, Hvl} 3 ··) gas columnar hollow for Gas virtual columnar portion extended Hg) and (HVG) are close, (4) columnar hollow for liquid _{(Hl 1, Hl 2, Hl} 3 ··) ejection direction central axis of _(Al 1, Al ₂ , Al ₃ ..) and the central axis (Ag) of the gas columnar hollow part (Hg) in the discharge direction are parallel to each other, (5) perpendicular to the central axis (Ag) of the gas columnar hollow part (Hg) Straight line having the shortest distance between the outer periphery of the gas columnar hollow portion (Hg) and the outer periphery of the liquid columnar hollow portion (Hl ₁ , Hl ₂ , Hl ₃ ...) “(L ₁ , L ₂ , L ₃ ...) Can be drawn only one” (Patent Document 2). In this spinning device, the spinning solution discharged from the liquid discharging unit and the gas discharged from the gas discharging unit are close and parallel to each other, and the spinning solution has one shearing force due to the gas and the accompanying airflow. Therefore, it was possible to stably spin a thinned fiber. However, since the liquid discharge part is located at an interval, there is a problem that a difference is easily generated between the amount of accumulated fibers immediately below the liquid discharge part and the amount of accumulated fibers between the liquid discharge parts.

Further, the applicant of the present application, as shown in FIG. 9, “at _{least one} liquid discharging part (El ₁ , El ₂ , El ₃ , El ₄ , El ₅ , El ₆ ) capable of discharging the spinning liquid, It is located upstream of the liquid discharge part (El ₁ , El ₂ , El ₃ , El ₄ , El ₅ , El ₆ ) and has one gas discharge part (Eg) that can discharge gas, and satisfies the following conditions A spinning device having one or more spinning units (Nu), (1) surrounded by a wall material having a liquid discharge part (El ₁ , El ₂ , El ₃ , El ₄ , El ₅ , El ₆ ) as an end (2) The liquid columnar hollow part is extended, (2) The gas columnar hollow part surrounded by the wall material is provided. (3) The liquid columnar hollow part is extended. Each liquid virtual columnar part and the gas virtual columnar part obtained by extending the gas columnar hollow part are the same. (4) The discharge column central axis of each liquid columnar hollow and the discharge column central axis of each gas column hollow are parallel to each other, (5) The center of the gas column hollow When cutting along a plane perpendicular to the axis, draw two or more straight lines each having the shortest distance between the outer periphery of the cut surface of the gas columnar hollow part and the outer periphery of the cut surface of each liquid columnar hollow part. (6) When cut along a plane perpendicular to the central axis of the gas columnar hollow part, the outer periphery of the cut surface of the liquid columnar hollow part with respect to the outer periphery of the cut surface of the gas columnar hollow part The length of the outer circumference of the cut surface of each liquid columnar hollow portion that can draw the straight line having the shortest distance from the outer circumference is 50% or less of the outer circumference length of each cut surface of the liquid columnar hollow portion "(patent Reference 3) was proposed. In this spinning device, the spinning solution discharged from the liquid discharging unit and the gas discharged from the gas discharging unit are close and parallel to each other, and the shearing force due to the gas and the accompanying airflow acts on the spinning solution. The fiber having a reduced diameter can be spun stably. However, as in Patent Document 2, since the liquid discharge portion is located at an interval, a difference is generated between the amount of accumulated fibers immediately below the liquid discharge portion and the amount of accumulated fibers between the liquid discharge portions. There was a problem that it was easy.

JP 2005-515316 A (summary, Table 1, etc.) JP 2011-132654 A (Claim 1, FIG. 1 etc.) JP 2011-168928 A (Claim 1, FIG. 6 etc.)

  This invention is made | formed in view of the above problems, and it aims at providing the method which can manufacture the fiber assembly with which the fiber amount of the fiber with a small fiber diameter was equal, and its manufacturing apparatus.

  The invention according to claim 1 of the present invention is directed to “a fiber formed by applying a gas and / or an electric field to a liquid pool of a resin liquid moving by its own weight in a direction crossing the moving direction of the liquid pool. It is a method for producing a fiber assembly, which is characterized by being collected by a moving collector. "

  The invention according to claim 2 of the present invention is a spinning device capable of forming a liquid pool of a resin liquid that moves by its own weight and capable of forming fibers by applying a gas and / or an electric field to the resin liquid, and An apparatus for producing a fiber assembly, comprising: a collector that moves in a direction intersecting with a moving direction of the liquid pool and collects the fibers. "

  In the invention according to claim 1 of the present invention, since fibers are formed by applying a gas and / or an electric field to a liquid pool of a resin liquid that moves by its own weight, a fiber assembly having an equal amount of fibers can be manufactured. . In other words, the state in which the liquid reservoir corresponding to the liquid discharge part is continuously moving under its own weight corresponds to the liquid discharge part being continuously moved, so that a fiber assembly with an equal fiber amount is manufactured. it can.

  The invention according to claim 2 of the present invention can form a liquid pool of a resin liquid that moves by its own weight, and can be fiberized by a spinning device that can form fibers by applying a gas and / or an electric field to the resin liquid. Therefore, a fiber assembly with an equal amount of fibers can be manufactured. In other words, the state in which the liquid reservoir corresponding to the liquid discharge part is continuously moving under its own weight corresponds to the liquid discharge part being continuously moved, so that a fiber assembly with an equal fiber amount is manufactured. it can.

Top view of the fiber assembly manufacturing apparatus of the present invention The side view from the collection body movement direction in the fiber assembly manufacturing apparatus of FIG. Schematic perspective view of the spinning device of the present invention FIG. 3 is a plan view from the liquid discharge unit side in the spinning device of FIG. (A) Enlarged view of circle E in FIG. 2 (b) Enlarged view of circle E in FIG. 2 after elapse of a certain time from the state of (a) (c) In FIG. 2 after elapse of a certain time from the state of (b) Enlarged view of circle E Front view of liquid supply plate Schematic diagram of a conventional non-woven mat manufacturing device (A) Schematic partial perspective view of a conventional spinning device (b) Partial cutaway view at plane C in (a) Partial schematic cutaway view of a conventional spinning device

  FIG. 1 is a top view of a fiber assembly manufacturing apparatus, and FIG. 2 is a side view of the fiber assembly manufacturing apparatus in FIG. 3 will be described with reference to FIG. 3 which is a schematic perspective view of the apparatus, and FIG. 4 which is a plan view from the liquid discharge part side (D direction in FIG. 3) in the spinning apparatus of FIG.

  As shown in FIG. 1, the apparatus for producing a fiber assembly according to the present invention moves in a spinning device 10 capable of spinning fibers, in a direction perpendicular to the length direction of the spinning device 10 (direction A in FIG. 1). 10, a collecting body 20 that can collect the fibers spun by 10, and a winding roll 40 that can take up the fiber assembly 30 that is collected and formed on the collecting body 20. As shown in FIGS. 3 and 4, a liquid discharge portion 16 that extends in a straight line and can discharge a resin liquid, and a gas discharge portion 17 that extends in a straight line in parallel with the liquid discharge portion 16 and can discharge a gas. As shown in FIG. 2, the liquid discharge unit 16 is disposed in an inclined state so that the distance from the collector 20 having a collection surface parallel to the horizontal plane is shortened from one end to the other end of the liquid discharge unit 16. .

  More specifically, the spinning device 10 includes a liquid supply plate 11, a gas supply plate 12, a liquid-gas separator 13, a liquid spacer 14, and a gas spacer 15, as shown in FIGS. In addition, by interposing a liquid spacer 14 between the liquid supply plate 11 and the liquid-gas separator 13, a liquid discharge portion 16 that can supply a resin liquid and discharge the resin liquid is formed. By interposing a gas spacer 15 between 12 and the liquid-gas separator 13, a gas discharge portion 17 capable of supplying gas and discharging gas is formed. Therefore, the resin liquid discharged from the liquid discharge unit 16 and the gas discharged from the gas discharge unit 17 are in a state of being separated by a distance corresponding to the thickness of the liquid-gas separator 13 immediately after the discharge. The gas supply plate 12 and the gas spacer 15 are arranged so that the gas discharge unit 17 is located upstream of the liquid discharge unit 16. In addition, a resin liquid supply device is connected so that the resin liquid can be supplied to the liquid supply space formed by interposing the liquid spacer 14 between the liquid supply plate 11 and the liquid-gas separator 13. A gas supply device is connected so that a gas can be supplied to a gas supply space formed by interposing a gas spacer 15 between the gas separator 12 and the liquid-gas separator 13.

Therefore, when the resin liquid is supplied to the liquid supply space of the spinning device 10 of the manufacturing apparatus of the fiber assembly 30 as described above, the resin liquid reaches the liquid discharge unit 16 through the liquid supply space. Since it is a rectangular shape that extends in a straight line, it is difficult for the resin liquid to be uniformly discharged from the liquid discharge portion 16, and the resin liquid is discharged in a dot shape, that is, the liquid reservoirs L ₁ , L ₂ , L _3. Is formed (see FIG. 5A). On the other hand, when gas is supplied to the gas supply space, the gas reaches the gas discharge part 17 through the gas supply space and is discharged from the gas discharge part 17. The discharged gas is close to the resin liquid reservoirs L ₁ , L ₂ , L ₃ ..., And this gas causes the resin liquid reservoirs L ₁ , L ₂ , L ₃ . Since a shearing force can be applied, the resin liquid is fibrillated and flies toward the collector 20 (see FIG. 5A).

In this way, the liquid reservoirs L ₁ , L ₂ , L ₃ ... Are formed, but the liquid discharge portion 16 is inclined from one end to the other end. The liquid pools L ₁ , L ₂ , L ₃ ... Are moved in an inclined direction by their own weights (see FIG. 5B). In addition, since the resin liquid is supplied through the liquid supply space, the amount of resin in the liquid reservoir does not decrease even if the resin liquid is used. Further, as the resin liquid reservoirs L ₁ , L ₂ , L ₃ ... Move, a new resin liquid reservoir L ₀ is formed at one end of the liquid discharge portion 16 (FIG. 5B). reference).

Similarly, when the time further elapses, the resin liquid reservoirs L ₀ , L ₁ , L ₂ , L ₃ .. A liquid reservoir L- ₁ is formed (see FIG. 5C).

The fibers thus formed are orthogonal to the direction perpendicular to the length direction of the spinning device 10, that is, to the direction of movement of the resin liquid reservoirs L ₋₁ , L ₀ , L ₁ , L ₂ , L _3. The fiber aggregate 30 is formed by being collected by the collector 20 moving in the direction. And this fiber assembly 30 is wound up by the winding roll 40 located in the end of the collection body 20. As shown in FIG.

  As described above, according to the manufacturing apparatus as shown in FIGS. 1 to 5, the fiber is made into a fiber by applying a gas to the liquid pool of the resin liquid that continuously moves under its own weight, and the fiber that is made into fiber Since the collection is performed by the collection body 20 that moves in the direction orthogonal to the movement direction of the liquid pool, the fiber assembly 30 with an equal fiber amount can be manufactured.

  In the spinning device 10 in FIGS. 3 and 4, since the discharged resin liquid and the discharged gas can be discharged in parallel with each other, the shearing action due to the gas and the accompanying airflow can be efficiently applied, and stable. The fiber can be spun.

  As described above, in the spinning device 10 shown in FIGS. 3 and 4, the gas discharge unit 17 is located upstream of the liquid discharge unit 16, so that the resin liquid is prevented from winding up around the liquid discharge unit 16. it can. Therefore, it is possible to perform spinning for a long time without soiling the periphery of the liquid discharge unit 16. The distance between the gas discharge unit 17 and the liquid discharge unit 16 is not particularly limited, but is preferably 10 mm or less, and more preferably 5 mm or less. This is because if it exceeds 10 mm, the shearing force of the gas and the accompanying airflow with respect to the discharged resin liquid becomes insufficient, and it tends to be difficult to form fibers.

  In addition, since the gas discharge part 17 is located upstream from the liquid discharge part 16, and the resin liquid discharged from the liquid discharge part 16 and the gas discharged from the gas discharge part 17 are discharged in parallel, the gas In addition, it is possible to apply a shearing force due to the accompanying air flow and to spin fibers having relatively uniform fiber diameters, but if the fiber diameter distribution is not a problem, the gas discharge unit 17 and the liquid discharge unit 16 May be on the same plane, or the gas discharge part 17 may be downstream of the liquid discharge part 16. Further, the resin liquid and the gas need not be discharged so as to be parallel. For example, you may discharge so that gas may be sprayed with respect to a resin liquid.

  3 and 4, the discharged resin liquid and the discharged gas are separated by a distance corresponding to the wall thickness of the liquid-gas separator 13, but this separation distance is 2 mm or less. It is preferable that it is 1 mm or less. This is because when this distance exceeds 2 mm, the shearing force of the gas and the accompanying airflow hardly acts and the fiber tends to be difficult to be formed.

  In the spinning device 10 of FIGS. 3 and 4, the liquid discharge unit 16 and the gas discharge unit 17 extend in a straight line, but need not be in a straight line. For example, the liquid discharge unit 16 and the gas discharge unit 17 may be curved, wavy, circular, X-shaped, U-shaped, spiral, triangular, quadrangular, or a combination of these. As long as is continuous, the same effect is produced.

  3 and 4, the gas discharge unit 17 extends in a straight line parallel to the liquid discharge unit 16, but it is not necessary to be parallel. However, from the viewpoint of spinning a fiber having a uniform fiber diameter by applying the same amount of gas to any liquid pool, it is preferable that the liquid pools are parallel.

  3 and 4, the liquid supply plate 11, the gas supply plate 12, the liquid-gas separator 13, the liquid spacer 14, and the gas spacer 15 constituting the spinning device 10 are made of metal or resin. The material is not particularly limited.

  3 and 4 includes a liquid supply plate 11, a gas supply plate 12, a liquid-gas separator 13, a liquid spacer 14, and a gas spacer 15. The spinning apparatus 10 moves by its own weight. As long as it has the liquid discharge part 16 which can form the liquid reservoir of the resin liquid which can be formed, and the gas discharge part 17 which can make gas act continuously with respect to this moving liquid reservoir, it is comprised from these materials. There is no need.

  Further, in the spinning device 10 of FIGS. 3 and 4, one gas discharge portion 17 corresponds to one liquid discharge portion 16, but gas discharge portions are provided on both sides of one liquid discharge portion. Alternatively, a liquid discharge part may be provided on both sides of one gas discharge part.

  In the manufacturing apparatus in FIG. 1, a resin liquid supply apparatus and a gas supply apparatus are connected to the spinning apparatus 10. However, as the resin liquid supply apparatus, when the resin liquid is obtained by dissolving a polymer in a solvent. For example, a syringe, a stainless steel tank, a plastic tank, or a resin bag made of a vinyl chloride resin, a polyethylene resin, or the like can be used. And a metal syringe heated by an extruder or a heater. Examples of the gas supply device include a compressor, a gas cylinder, and a blower when the gas is at room temperature. When the gas is a heated gas, the gas supply apparatus includes, for example, a compressor and a gas cylinder connected to a heater. And blowers.

  Although the collection body 20 in FIG. 1 consists of a conveyor, what is necessary is just what can collect a fiber directly, For example, a textile fabric, a knitted fabric, a net | network, a net | network, a drum, a belt, or a flat plate can be used as the collection body 20. FIG. In the present invention, since the gas is discharged, it is easy to collect the fibers on the collector by sucking the gas, and the breathable collector 20 is used so that the collected fibers are not disturbed. It is preferable to install a suction device on the surface opposite to the collection surface (the surface on the spinning device side) of the collection body 20.

  Moreover, although the collection body 20 in FIG. 1 is moving in the length direction of the spinning device 10, that is, the direction orthogonal to the moving direction of the liquid reservoir, it is not necessary to be in the orthogonal direction. However, the orthogonal direction is preferable because the fiber assembly 30 with a more uniform fiber amount can be manufactured.

  In the present invention, since the liquid pool of the resin liquid that moves under its own weight is made into a fiber, it is preferable that the collecting body 20 is disposed below the spinning device 10 in the direction of gravity. In addition, as shown in FIG. 2, the discharge direction of the resin liquid and the collection surface of the collection body 20 are not orthogonal to each other, but may be orthogonal to each other.

  As shown in FIG. 2, the spinning device 10 is in an inclined state so that the distance from the collector 20 having a collection surface parallel to the horizontal plane is shortened, but the inclination (α in FIG. 2) is a resin liquid. Therefore, it is preferable to adjust appropriately by experiment, because the viscosity varies depending on the viscosity, the discharge amount of the resin solution, the affinity of the resin solution with respect to the spinning device member, and the size and shape of the liquid discharge portion 16.

  As shown in FIG. 2, the liquid discharge portion 16 does not need to be inclined from one end to the other end. As shown in FIG. 6, the liquid discharge portion 16 extends from the central portion to both ends of the liquid supply plate 11. Even in a tilted state, the same effect is produced. That is, the liquid reservoir of the resin liquid generated in the central portion of the liquid supply plate 11 moves toward both ends of the liquid supply plate 11 by its own weight, but when it continuously moves, the shearing action due to the gas and the accompanying airflow is exerted. In response, it is possible to produce a fiber assembly 30 that is continuously fiberized and has an equal amount of fibers.

  Furthermore, in FIGS. 1-4, although it fiberizes with the gas discharged from the gas discharge part 17, it is not necessary to fiberize only by the effect | action of gas, and instead of or in addition to the effect | action of gas, an electric field is applied. By making it act, it can also be fiberized. For example, an electric field is applied to the liquid pool of the resin liquid by applying a voltage to the liquid supply plate 11 of the spinning device 10 or the resin liquid in the liquid supply space and grounding the collector 20. it can. By applying an electric field in this way, the liquid pool of the resin liquid tends to be fiberized, and due to the electrostatic repulsion between the fibers, a fiber bundle in which the fibers are bound to each other is not formed, and the individual fibers are dispersed. Since it can collect in a state, it is easy to manufacture the fiber assembly 30 with a uniform fiber diameter.

  Examples of a power source to which a voltage can be applied include a direct current high voltage generator and a Van de Graf electromotive machine. Further, the applied polarity may be positive or negative. Alternatively, the spinning device 10 may be grounded by applying to the collector 20. Alternatively, a voltage may be applied to both the collector 20 and the spinning device 10 so that an electric field is formed between the collector 20 and the spinning device 10. Moreover, it is not applied with respect to the collection body 20, but a counter electrode is arrange | positioned on the surface opposite to the collection surface of the collection body 20, a counter electrode is earth | grounded or applied, and an electric field is provided between the spinning apparatuses 10. It can also be formed.

  In addition, when an electric field is applied to the resin liquid by applying a voltage, if all the resin liquid reservoirs are not at the same distance from the collector, the resin liquid reservoirs with a short distance are preferentially used. Since the spinning tends to be difficult to spin over the entire liquid discharge part, when an electric field is applied, the distance between the liquid discharge part and the collection surface of the collector is the same throughout the liquid discharge part. It is preferable to tilt the assembly.

  The manufacturing apparatus of the fiber assembly 30 in FIGS. 1 and 2 is an open system, but the spinning apparatus 10, the collection body 20, and the winding roll 40 can be housed in a spinning container to form a closed system. When the resin liquid is dissolved in a solvent, the solvent is volatilized during spinning, but if the system is a closed system, diffusion of the solvent can be prevented and reused in some cases.

  In this way, when storing in the spinning container, it is preferable to connect an exhaust device capable of exhausting the gas in the spinning container. When the resin solution is dissolved in a solvent, spinning is performed, the solvent vapor concentration in the spinning vessel gradually increases, and as a result of suppressing the evaporation of the solvent, fiber diameter variation is likely to occur. Moreover, it is because it tends to become difficult to fiberize. Although this exhaust apparatus is not specifically limited, For example, it can be a fan installed in the exhaust port. Further, when supplying gas to the spinning container by the container gas supply device, the exhaust device is not necessarily required because the same amount of gas can be discharged simply by providing an exhaust port. In addition, when exhausting by the exhaust device, it is preferable that the exhaust amount is exhausted by the same amount as the total gas supply amount from the gas supply device and the container gas supply device. This is because if the total supply amount and the exhaust amount are different, the pressure in the spinning vessel changes, so that the evaporation rate of the solvent changes and the fiber diameter is likely to vary. The suction device can also be used as an exhaust device.

  When a container gas supply device capable of supplying gas with adjusted temperature and humidity is connected to the spinning container, the solvent vapor concentration in the spinning container can be stabilized, and fibers with small variations in fiber diameter can be spun. Examples of the container gas supply device include a propeller fan, a sirocco fan, an air compressor, and a blower.

  In FIG. 1, the fiber assembly 30 formed by collecting the fibers is directly wound up by the winding roll 40, but before the winding, an apparatus for binding the fiber assembly 30 is arranged. can do. For example, a device for applying and drying a binder, a heat treatment device capable of fusing fibers, a entanglement device capable of tangling fibers, and the like can be disposed.

  Further, in FIG. 1, only one set of spinning devices 10 is depicted, but two or more sets of spinning devices can be arranged. For example, it is preferable to arrange the spinning device in parallel with the conveying direction of the fiber assembly 30. By arranging in this way, the productivity of the fiber assembly 30 can be increased. In particular, the spinning device is preferably arranged so that the movement directions of the liquid pools in adjacent spinning devices are opposite to each other in the transport direction. By arrange | positioning in this way, the fiber assembly 30 with more equal fiber quantity can be manufactured.

  When a fiber assembly is manufactured using the manufacturing apparatus of the present invention, the flow rate of 100 m / sec. It is preferable to discharge the above gas. A flow rate of 100 m / sec. By discharging the gas described above, it is possible to suppress the generation of droplets and to manufacture a fiber assembly 30 made of thin fibers with uniform fiber diameters. More preferably, the flow rate is 150 m / sec. The above gas is discharged, more preferably a flow rate of 200 m / sec. The above gas is discharged. The upper limit of the gas flow rate is not particularly limited as long as it is a flow rate that allows stable spinning.

  In order to discharge the gas at such a flow rate, for example, the gas may be supplied from the compressor to the gas supply space. In addition, although the kind of gas is not specifically limited, air, nitrogen gas, argon gas, etc. can be used and it is economical when it is air among these. The temperature of the gas varies depending on the resin liquid and is not particularly limited. However, in the case of a resin liquid in which a polymer is dissolved in a solvent, it is economically preferable that the temperature is normal, and the polymer itself is heated and melted. In the case where the resin liquid is a liquid, the temperature at which the resin liquid and the gas are in contact is from 100 ° C. lower than the temperature of the heat-melted resin liquid to 100 ° C. higher than the temperature of the heat-melted resin liquid. A gas with a temperature in the range is preferred. In the case of a gas having a temperature lower than the temperature of the heated and melted resin liquid, the solidification of the fiber can be promoted by a cooling action. On the other hand, in the case of a gas having a temperature higher than that of the heated and melted resin liquid, In the flying space from the liquid discharge part 16 to the collector 20, the shear force of the gas and the accompanying airflow can be applied to the resin liquid.

  In addition, cooling gas etc. can be supplied with respect to the flying space of the fiber between the spinning apparatus 10 and the collection body 20, and a fiber can be cooled, and solidification of a fiber can be accelerated | stimulated. Moreover, heating gas can be supplied with respect to flight space, a fiber can be heated and heat-retained, and the solidification of a fiber can be suppressed.

  As the resin liquid that can be used in the present invention, a solution obtained by dissolving a desired polymer in a solvent or a solution obtained by heating and melting a desired polymer can be used.

  For example, as a resin solution in which the former polymer is dissolved in a solvent, polyethylene glycol, partially saponified polyvinyl alcohol, fully saponified polyvinyl alcohol, polyvinyl pyrrolidone, polylactic acid, polyester, polyglycolic acid, polyacrylonitrile, copolymerized polyacrylonitrile, polymethacryl Acid, polymethyl methacrylate, polycarbonate, polystyrene, polyamide, polyimide, polyethylene, polypropylene, polyethersulfone, polysulfone, fluororesin (polyvinylidene fluoride, copolymerized polyvinylidene fluoride, etc.), polyurethane, para- or meta-aramid, cellulose 1 type or 2 types or more of polymers such as water, acetone, methanol, ethanol, propanol, isopropanol, tetrahydrofuran, Tyl sulfoxide, 1,4-dioxane, pyridine, N, N-dimethylformamide, N, N-dimethylacetamide, N-methyl-2-pyrrolidone, acetonitrile, formic acid, toluene, benzene, cyclohexane, cyclohexanone, carbon tetrachloride, chloride What was melt | dissolved in 1 type, or 2 or more types of solvents, such as a methylene, chloroform, a trichloroethane, ethylene carbonate, diethyl carbonate, a propylene carbonate, can be used.

The spinning viscosity of a resin solution obtained by dissolving this polymer in a solvent is preferably in the range of 10 to 10000 mPa · s, more preferably in the range of 20 to 8000 mPa · s. When the viscosity is less than 10 mPa · s, the viscosity is too low and the spinnability tends to be difficult to become a fiber, and when the viscosity exceeds 10000 mPa · s, the resin liquid is not easily stretched and tends to be a fiber . Therefore, even when the viscosity exceeds 10,000 mPa · s at normal temperature, it can be used as long as it is within the above viscosity range by heating the resin liquid. Conversely, even if the viscosity is less than 10 mPa · s at room temperature, it can be used as long as it falls within the above-mentioned viscosity range by cooling the resin liquid. The “viscosity” in the present invention refers to a value at a shear rate of 100 s ⁻¹ measured at the same temperature as in spinning using a viscosity measuring device.

  On the other hand, as a polymer that can constitute a heat-melted resin liquid, for example, polyolefin (polypropylene, polyethylene, polypropylene-polyethylene copolymer, polymethylpentene, etc.), polyester (aliphatic polyester, aromatic polyester), Acrylic (polyacrylonitrile, copolymerized polyacrylonitrile), cellulose, polyvinyl alcohol, ethylene vinyl alcohol copolymer, polyvinyl chloride, polyvinylidene chloride, polycarbonate, polystyrene, polyurethane, polylactic acid, polyamide (nylon 6, nylon 66) , Nylon 12, nylon 610), polyacetal, aramid, polyethersulfone, polysulfone, or fluororesin (polyvinylidene fluoride, copolymerized polyvinylidene fluoride, etc.) ), Polyphenylene sulfide, polyether ether ketone, etc. may be used as a mixture of two or more.

The spinning temperature range of the resin liquid in which the polymer is heated and melted is preferably in the range from the melting point of the polymer to a temperature 200 ° C higher than the melting point, from the temperature 20 ° C higher than the melting point to the temperature 100 ° C higher than the melting point. More preferably, it is the range. This is because in the case of a polymer exhibiting temperature dependency, the polymer is thermally decomposed at a temperature higher than 200 ° C. higher than the melting point, making spinning difficult. Further, the shear rate applied to the polymer during spinning is preferably from 1～10000S ^-1, and more preferably a shear rate 50~5000s ^-1. In the case of a polymer exhibiting pressure dependency, if the shear rate is less than 1 s ⁻¹ , the discharge is not stable, and if it exceeds 10000 s ⁻¹ , a high discharge pressure is required and the discharge tends to be difficult. is there. In the above temperature range and shear rate range, the spinning viscosity is preferably in the range of 10 to 10000 mPa · s, and more preferably in the range of 20 to 8000 mPa · s. If the viscosity is less than 10 mPa · s, the viscosity is too low and the spinnability is poor, and there is a tendency that the fiber is difficult to be formed. If the viscosity exceeds 10,000 mPa · s, the resin liquid is difficult to be stretched and is not likely to be a fiber. Because there is. Accordingly, even when the viscosity exceeds 10,000 mPa · s at the time of melting, it can be used as long as it falls within the above viscosity range by heating the resin liquid. Conversely, even when the viscosity is less than 10 mPa · s at the time of melting, it can be used as long as it falls within the above-mentioned viscosity range by cooling the resin liquid.

  As described above, when a liquid discharge part is provided on both sides of one gas discharge part, different types of discharge can be obtained by changing the discharge condition from one liquid discharge part and the discharge condition from the other liquid discharge part. A fiber assembly in which fibers are mixed can be manufactured. For example, the size of the liquid discharge part is different, the distance of the liquid discharge part from the gas discharge part is different, the discharge amount of the resin liquid is different, the concentration of the resin liquid is different, the resin liquid constituent polymer is different, the viscosity of the resin liquid The resin liquid is different, the resin liquid is composed of two or more polymers, the blending ratio is different, the resin liquid is composed of two or more solvents, the blending ratio is different, The temperature of the resin is different, the method of preparing the resin liquid is different (for example, the resin liquid dissolved in the solvent and the resin liquid heated and melted), the type and / or amount of the additive added to the resin liquid is different, etc. When one or more of these are discharged under different conditions, a fiber assembly in which different types of fibers are mixed can be produced.

  In the present invention, a function can also be imparted to the fiber aggregate by supplying powder, fiber, and / or fiber aggregate to the flying fiber and mixing them.

  For example, as powder, activated carbon (for example, steam activated carbon, alkali-treated activated carbon, acid-treated activated carbon, etc.), inorganic particles (for example, manganese dioxide, iron oxide, copper oxide, nickel oxide, cobalt oxide, zinc oxide, titanium-containing oxide) Materials, zeolites, catalyst-supporting ceramics, silica, etc.), ion exchange resins, plant seeds, and the like.

  Recycled fibers such as rayon, polynosic and cupra, semi-synthetic fibers such as acetate fibers, nylon fibers, vinylon fibers, vinylidene fibers, polyvinyl chloride fibers, polyester fibers, acrylic fibers, polyethylene fibers, polypropylene fibers, polyurethane fibers, etc. Synthetic fibers, inorganic fibers such as glass fibers and carbon fibers, plant fibers such as cotton and hemp, and animal fibers such as wool and silk.

  Examples of the fiber aggregate include the aggregate of the same or different fibers. The aggregate state of the fiber aggregate is not particularly limited. For example, the fiber is entangled, the fibers are bonded, the fibers are fused, the fibers are twisted into a yarn. State, etc.

  Examples of the present invention will be described below, but the present invention is not limited to the following examples.

Example 1
(Preparation of resin solution)
A resin liquid [viscosity: 420 mPa · s (23 ° C.)] in which copolymer polyacrylonitrile was dissolved in N, N-dimethylformamide so as to have a concentration of 13 mass% was prepared.

(Preparation of fiber assembly manufacturing equipment)
As shown in FIGS. 1 and 2, a spinning device 10 having the following configuration, a conveyor (a width of 150 mm, a length of 300 mm in the moving direction), a suction device, and a winder as a collecting body 20 made of a stainless metal mesh (70 mesh). A paper tube was prepared as the roll 40.

(1) Resin liquid supply device: Syringe (2) Gas supply device: Compressor (3) Liquid supply plate 11: Stainless steel plate having a length of 35 mm, a width of 60 mm, and a thickness of 3 mm (4) Gas supply plate 12: Vertical 30 mm, 60 mm wide, 3 mm thick stainless steel plate (5) Liquid-gas separator 13: Vertical 35 mm, 60 mm wide, 0.3 mm thick stainless steel plate (6) Liquid spacer 14: Vertical 35 mm, horizontal Stainless steel plate 5 mm, thickness 0.3 mm (7) Gas spacer 15: Vertical 30 mm, width 5 mm, stainless steel plate 0.2 mm in thickness (8) Liquid discharge part 16: width 0.3 mm, length 50 mm straight line (9) gas discharge part 17: width 0.2 mm, length 50 mm straight line (10) position of gas discharge part 17: 5 mm from liquid discharge part 16 Flow side (11) fluid relationship of the discharge portion 16 and the gas discharge section 17: parallel

  Next, the collection body 20 is arranged so that the collection surface is horizontal, and the liquid discharge part 16 of the spinning device 10 is inclined by 5 ° (α in FIG. 2) with respect to the collection surface of the collection body 20. It arrange | positioned so that the longitudinal direction of the discharge part 16 might orthogonally cross with respect to the moving direction of the collection body 20, and it was set as the fiber assembly manufacturing apparatus. In addition, the spinning device 10 was disposed above the collecting body 20 in the direction of gravity so that the closest distance between the liquid discharge unit 16 and the collecting surface was 100 mm. Further, a suction device having a suction port of 60 mm in the width direction of the collector 20 and 30 mm in the moving direction of the collector 20 was disposed on the opposite side of the collection surface of the collector 20.

(Manufacture of fiber assemblies)
The resin liquid is supplied at 3 mL / min. In the liquid supply space of the fiber assembly manufacturing apparatus. In this manner, a liquid reservoir of the resin liquid is formed in the liquid discharge portion 16. At the same time, compressed air is supplied to the gas supply space at a pressure of 0.25 MPa at 250 L / min. The room temperature air was discharged from the gas discharge unit 17 to fiberize the liquid reservoir. This fiberized fiber was 125 mm / min. The fiber assembly 30 (weight per unit area: 5 g / m ² , thickness: 25 μm, average fiber diameter: 400 nm, width: 60 mm) was produced by collecting with the collection body 20 moving in the above. When collecting the fibers, using a roots blower connected to the suction port of the suction device, 1 m ³ / min. Air was sucked in at a flow rate of.

A sample piece of 200 mm in the flow direction (moving direction of the collecting body) and 60 mm in the width direction (direction orthogonal to the moving direction of the collecting body) was sampled from the manufactured fiber assembly 30, and further in the width direction. _Twelve subdivided sample pieces T _{1 to} T ₁₂ having a flow direction of 200 mm and a width direction of 5 mm were prepared by cutting at intervals of 5 mm. Then, since the length of the liquid discharge part was 50 mm, the mass of the subdivision test pieces T _{2 to} T ₁₁ excluding the subdivision test pieces T ₁ and T ₁₂ at both ends was measured, and the basis weight (per 1 m ² The mass per unit area was 5 ± 0.05 g / m ² , and the fiber aggregate had a small variation in the fiber amount in the width direction.

(Comparative Example 1)
Although it tried to manufacture a fiber assembly on the same conditions as Example 1 except having used the spinning device which consists of the following composition similar to Drawing 7, it cannot be made into a continuous fiber, shot and There were many droplets and a uniform fiber assembly could not be produced.

(1) Resin liquid supply device: syringe (2) Gas supply device: compressor (3) Liquid supply plate (122 in FIG. 7):
Stainless steel plate (4) gas supply plate (132 in FIG. 7) having a length of 35 mm, a width of 60 mm, and a thickness of 3 mm:
Stainless steel plate with a length of 35 mm, a width of 60 mm, and a thickness of 3 mm (5) liquid-gas separator (112 in FIG. 7):
Stainless steel plate 30mm long, 60mm wide, 0.3mm thick (6) Liquid spacer:
Stainless steel plate of length 35mm, width 5mm, thickness 0.3mm (7) Gas spacer:
Stainless steel plate with a length of 30 mm, a width of 5 mm, and a thickness of 0.2 mm (8) Liquid / gas discharge part (120 in FIG. 7):
Position of outlet end portion (116) of straight line (9) liquid-gas separator 112 having a width of 0.8 mm and a length of 50 mm:
5mm upstream from the liquid / gas discharge part

(Comparative Example 2)
As shown in FIG. 8, a spinning device having the following configuration, a conveyor (width 150 mm, length 300 mm in the moving direction) made of a stainless steel metal mesh (70 mesh) as a collector, a suction device, and a paper tube as a take-up roll Prepared.

(1) Spinning liquid supply device: Syringe (2) Gas supply device: Compressor (3) Liquid discharge nozzle group Nl _{1 to} Nl ₅ : Metal (3) -1 Liquid discharge part El _{1 to} El ₅ : 0.3 mm Circular (3) -2 liquid columnar hollow part Hl _{1 to} Hl ₅ : 0.3 mm diameter cylindrical shape (3) -3 Liquid discharge nozzle outer diameter: 0.55 mm (cross-sectional area: 0.07 mm ² )
(3) -4 Number of liquid discharge nozzles: 6 (4) Gas discharge plate Pg: metal (4) -1 Gas discharge portion Eg: width 0.2 mm, length 50 mm
(4) -2 Columnar hollow portion Hg for gas: a rectangular parallelepiped shape having a width of 0.2 mm, a length of 50 mm, and a depth of 35 mm (4) -3 thickness of a member constituting the gas discharge plate Pg: 1 mm
(4) -4 Number of gas discharge plates Pg: 1 set (4) -5 Position: All liquid discharge portions El _{1 to} El ₅ are located 5 mm downstream of the gas discharge portions Eg, and the gas discharge plates Pg Arranged so that the outer wall of one side and the outer wall surface of the liquid discharge nozzle are in contact with each other and the interval between the liquid discharge nozzles is 10 mm (5) Liquid discharge direction central axes Al _{1 to} Al ₅ and gas discharge direction central axis Ag: parallel (6 ) When cut along a plane perpendicular to the central axis of the gas columnar hollow part Hg, the inner periphery of the cut surface of the gas columnar hollow part Hg and the inner periphery of the cut surface of the liquid columnar hollow parts Hl _{1 to} Hl ₅ Number of straight lines with the shortest distance to each: 1 each

Next, the collection body is arranged so that the collection surface is horizontal, and the liquid discharge portions El _{1 to} El _{5 of} the spinning device are parallel to the collection surface of the collection body and the liquid discharge portions El _{1 to} El ₅ are arranged. It arrange | positioned so that a direction might orthogonally cross with respect to the moving direction of the collection body 20, and it was set as the fiber assembly manufacturing apparatus. The spinning device was arranged above the collector in the direction of action of gravity so that the distance between the liquid discharge portions El _{1 to} El ₅ and the collection surface was 100 mm. A suction device having a suction port of 60 mm in the width direction of the collector and 30 mm in the moving direction of the collector was arranged on the side opposite to the collection surface of the collector.

(Manufacture of fiber assemblies)
The same resin liquid as that of Example 1 was added to the columnar hollow portions for liquid H1 _{1 to} Hl ₅ of this fiber assembly manufacturing apparatus at 3 mL / min. The resin liquid was discharged from the liquid discharge portions El _{1 to} El ₅ . At the same time, compressed air is applied to the gas columnar hollow Hg at a pressure of 0.25 MPa at 250 L / min. And air at normal temperature was discharged from the gas discharge portion Eg to fiberize the resin liquid. This fiberized fiber was 150 mm / min. The fiber aggregate (weight per unit area: 5 g / m ² , thickness: 25 μm, average fiber diameter: 400 nm, width: 60 mm) was produced. When collecting the fibers, using a roots blower connected to the suction port of the suction device, 1 m ³ / min. Air was sucked in at a flow rate of.

A sample piece of 200 mm in the flow direction (the moving direction of the collecting body) and 60 mm in the width direction (the direction orthogonal to the moving direction of the collecting body) was sampled from the manufactured fiber assembly, and further 5 mm in the width direction. _Twelve subdivided sample pieces T _{1 to} T ₁₂ having a flow direction of 200 mm and a width direction of 5 mm were prepared by cutting at intervals. Then, since the distance between the liquid discharge nozzles at both ends was 50 mm, the mass of the subdivided test pieces T _{2 to} T ₁₁ excluding the subdivided test pieces T ₁ and T ₁₂ at both ends was measured, and the basis weight (1 m ² The mass per unit area) was calculated, and the basis weight was 5 ± 1.2 g / m ² , and the fiber aggregate had a small variation in the fiber amount in the width direction.

  According to the production method of the present invention, it is possible to produce a fiber assembly in which the amount of fibers having a small fiber diameter is uniform. The fiber assembly produced by the production method of the present invention includes, for example, filter media such as air filters, liquid filters and blood filters, separators for electrochemical elements such as battery separators and separators for capacitors, electrode materials, and membrane supports. , Semiconductor substrates, flexible display substrates, heat insulating materials, soundproofing materials, cell culture carriers, wound materials, drug delivery system materials, sensor chips, smart fabrics, and the like.

DESCRIPTION OF SYMBOLS 10 Spinning device 11 Liquid supply plate 12 Gas supply plate 13 Liquid-gas separator 14 Liquid spacer 15 Gas spacer 16 Liquid discharge part 17 Gas discharge part 20 Collecting body 30 Fiber assembly 40 Winding roll 112 First member 122 Second Member 132 Third member 114 Supply end portion of first member 124 Supply end portion of second member 134 Supply end portion of third member 116 Counter outlet end portion of first member 126 Counter exit end portion of second member 136 Third Opposite outlet end of member 118 First supply slit 138 First gas slit 120 Gas jet space Nl ₁ , Nl ₂ , Nl ₃ Liquid discharge nozzle Pg Gas discharge plate El ₁ , El ₂ , El ₃ , El ₄ , El ₅ , El ₆ liquid discharge part Eg gas discharge part Hl ₁ , Hl ₂ , Hl ₃ liquid columnar hollow part Hg gas columnar hollow part H vl ₁ , Hvl ₂ , Hvl ₃ liquid virtual columnar part Hvg gas virtual columnar part Al ₁ , Al ₂ , Al ₃ discharge direction central axis (liquid)
Ag discharge direction central axis (gas)
Ng gas discharge nozzle L ₁ , L ₂ , L ₃ The distance between the outer peripheries is the shortest straight line Nu spinning unit

Claims (2)

The fiber formed by applying a gas and / or an electric field to the liquid pool of the resin liquid moving by its own weight is collected by a collector that moves in a direction intersecting the moving direction of the liquid pool. A method for producing a fiber assembly. A liquid reservoir that can move under its own weight can be formed, and a spinning device that can form fibers by applying a gas and / or an electric field to the resin liquid, and a direction that intersects the moving direction of the liquid reservoir And a collecting body capable of collecting the fibers.

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