US20210025081A1 - Nanofiber collection device, nanofiber collection method, and nanofiber accumulation/molding apparatus and accumulation/molding method therefor - Google Patents

Nanofiber collection device, nanofiber collection method, and nanofiber accumulation/molding apparatus and accumulation/molding method therefor Download PDF

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Publication number
US20210025081A1
US20210025081A1 US16/644,681 US201816644681A US2021025081A1 US 20210025081 A1 US20210025081 A1 US 20210025081A1 US 201816644681 A US201816644681 A US 201816644681A US 2021025081 A1 US2021025081 A1 US 2021025081A1
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United States
Prior art keywords
collecting
nanofiber
peel
bars
collecting mechanism
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Abandoned
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US16/644,681
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English (en)
Inventor
Morihiko Ikegaya
Hiroyoshi SOTA
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M Techx Inc
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M Techx Inc
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Priority claimed from JP2017170641A external-priority patent/JP2019044307A/ja
Priority claimed from JP2017194709A external-priority patent/JP6517900B2/ja
Application filed by M Techx Inc filed Critical M Techx Inc
Publication of US20210025081A1 publication Critical patent/US20210025081A1/en
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D7/00—Collecting the newly-spun products
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/04—Dry spinning methods
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/736—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged characterised by the apparatus for arranging fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)

Definitions

  • the present invention relates to a device and method for collecting nanofibers drawn in the form of fibers with a fine diameter.
  • the present invention relates to a device and method for collecting nanofibers that collect nanofibers drawn in the form of fibers with a fine diameter while forming in a predetermined shape.
  • the present invention relates to a device and method for collecting nanofibers with greatly improved nanofiber production efficiency.
  • the present invention also relates to a device and method for depositing and forming nanofibers that deposit nanofibers while forming in a predetermined shape, the nanofibers produced by discharging a molten resin or a dissolved resin to a gas flow and drawing in the form of fibers with a fine diameter.
  • the present invention relates to a device and method for depositing and forming nanofibers that allow formation of a formation in a predetermined shape including a sheet shape, a mat shape, and a block shape by depositing a discharged nanofiber flow flowing on a gas flow while deflecting the flow by deflecting air from an air nozzle arranged in the vicinity.
  • PTL 1 describes a nanofiber production apparatus for producing and collecting fibers with a fine diameter.
  • the nanofiber production apparatus has a nanofiber generating device, a collecting device, a suction device, and a guide material.
  • the nanofiber generating device is provided with an air nozzle to generate high speed hot air and a blowing nozzle to discharge a polymer solution to the high speed hot air generated from the air nozzle or the vicinity of the high speed hot air.
  • the collecting device is provided on a downstream side of the nanofiber generating device and collects the nanofibers generated by the nanofiber generating device.
  • the suction device is provided on a downstream side of the collecting device and sucks gas.
  • the guide material is formed in a tubular shape and provided on a downstream side of the nanofiber generating device and an upstream side of the collecting device to pass the high speed hot air inside.
  • PTL 1 describes that “a filter substrate with nanofibers deposited thereon is heat treated, laminated, and integrated by a thermocompression roller and wound on a winding roll as a nanofiber filter material”. That is, PTL 1 describes that a nanofiber material deposited on a filter substrate of the collecting device is wound and collected on a winding roll of the collecting device. PTL 1, however, does not specifically describe the technique to produce a nanofiber material formed in a mat shape.
  • the collecting device in PTL 1 is specialized in collecting nanofibers in a long thin sheet shape to be wound on a roll and is not suitable for forming and efficiently collecting nanofibers in a relatively thick mat shape.
  • the nanofibers are deposited in a circular shape centered around the extension of the discharge nozzle.
  • a process of sucking with air from behind a sprayed surface (PTL 1) and the like are thus employed. Such a process, however, causes reduction in the suction force to the outer periphery of the sprayed surface as well as the amount of deposited nanofiber. Since nanofibers tend to be deposited near the center, it is difficult to form a formation in a predetermined shape with a uniform thickness.
  • a method of installing a plurality of nanofiber discharge nozzles in a wide area or a method of employing a process of moving a discharge nozzle including a melting section and a drive section is considered while causing problems of increasing in size and price of the device.
  • a general discharge nozzle has a mechanism of moving only in a uniaxial direction, whereas a mechanism of moving in a plurality of directions causes a very complex structure.
  • the present invention has been made in view of the above problems and it is thus an object thereof to provide a device and method for collecting nanofibers with greatly improved production efficiency by allowing efficient automatic collection of nanofibers in a mat shape of a relatively thick layer while forming in a predetermined shape.
  • a device for collecting nanofibers of the present invention is a device for collecting nanofiber produced by drawing a molten resin or a dissolved resin discharged to a gas flow in a fiber form with a fine diameter, the device including:
  • nanofiber collecting mechanism provided at the collecting mechanism rotation axis
  • a collecting mechanism drive motor configured to rotatively drive the collecting mechanism rotation axis
  • control mechanism configured to control the collecting mechanism drive motor to cause the nanofiber collecting mechanism to move between a collecting position to collect the nanofiber and a non-collecting position out of the collecting position by intermittently rotating the collecting mechanism rotation axis;
  • a peel off mechanism configured to peel off the nanofiber collected by the nanofiber collecting mechanism when the nanofiber collecting mechanism is in the non-collecting position.
  • the nanofiber collecting mechanism to move between a collecting position to collect the nanofiber and a non-collecting position out of the collecting position includes not only movement by rotation but also movement by sliding.
  • the nanofiber collecting mechanism has at least one collecting element provided at the collecting mechanism rotation axis.
  • the nanofiber collecting mechanism has a plurality of collecting elements provided at the collecting mechanism rotation axis at regular angular intervals.
  • the collecting element of the nanofiber collecting mechanism is configured with a collecting bar group having a plurality of bars aligned in parallel with each other along the collecting mechanism rotation axis.
  • the collecting bar group, herein, having the plurality of bars aligned in parallel with each other along the collecting mechanism rotation axis may be referred to as a nanofiber collecting element or a collecting element as an element of the nanofiber collecting mechanism.
  • the plurality of bars configuring the collecting bar group include bars located at both ends in an aligned direction to which respective shape retaining materials are fixed, the shape retaining materials retaining the collected nanofiber in a predetermined shape.
  • the nanofiber collecting mechanism has a fall prevention portion prepared by bending a distal end of each bar of the collecting bar group in a direction of rotation.
  • the peel off mechanism is configured with a peel off bar group having a plurality of bars aligned in parallel with each other, and
  • the plurality of bars of the peel off bar group are moved, when the collecting bar group configuring the collecting element of the nanofiber collecting mechanism is in the non-collecting position, to pass between the respective bars of the collecting bar group.
  • a nanofiber collecting mechanism has a collecting element configured with a collecting bar group having a plurality of bars aligned in parallel with each other,
  • a peel off mechanism configured to peel off nanofiber collected by the collecting bar group is configured with a peel off bar group having a plurality of bars aligned in parallel with each other,
  • a control mechanism is provided to control rotation of the nanofiber collecting mechanism and the peel off mechanism
  • the plurality of bars of the peel off bar group are arranged to pass between the respective bars of the collecting bar group during rotation of the peel off mechanism, and
  • control mechanism is configured to control the collecting element to move to the non-collecting position by intermittently rotating the nanofiber collecting mechanism and then to control the bars of the peel off bar group to pass between the respective bars of the collecting bar group by rotating the a peel off mechanism.
  • a method for collecting nanofibers of the present invention that collects nanofibers while forming in a predetermined shape is a method for collecting nanofiber while forming in a predetermined shape using a device for collecting nanofiber produced by drawing a molten resin or a dissolved resin discharged to a gas flow in a fiber form with a fine diameter, the method including:
  • the nanofiber collected by the collecting element is attached on a rear surface side in a direction of rotation of the nanofiber collecting mechanism and is recovered in a recovery container provided below when peeled off by the peel off mechanism.
  • a method for collecting nanofibers of the present invention is a method for collecting nanofiber used in a device for collecting nanofiber produced by drawing a molten resin or a dissolved resin discharged to a gas flow in a fiber form with a fine diameter, the device having a collecting mechanism rotation axis arranged horizontally, a collecting element of a nanofiber collecting mechanism provided on an outer peripheral surface of the collecting mechanism rotation axis, and a peel off mechanism configured to peel off the nanofiber collected by the collecting element below, wherein
  • the collecting element is moved between a collecting position on a gas flow and a non-collecting position out of the gas flow by intermittently rotating the collecting mechanism rotation axis, and
  • the nanofiber collected by the collecting element is peeled off below by the peel off mechanism when the collecting element is in the non-collecting position.
  • a method for collecting nanofiber of the present invention includes a procedure of following (a) through (e):
  • nanofiber is discharged from an outlet of a nanofiber discharge device, the device configured to produce nanofiber by discharging a molten or dissolved resin to a hot air flow and drawing in a fiber form with a fine diameter, to a nanofiber collecting mechanism, the collecting mechanism configured by aligning a plurality of bars in parallel and configured to be intermittently rotatively driven in a predetermined direction, on a rear surface side in a direction of rotation of the nanofiber collecting mechanism;
  • a peel off mechanism is rotated to the nanofiber collected and formed in the predetermined shape by the nanofiber collecting mechanism to peel off the nanofiber attached to the nanofiber collecting mechanism;
  • the nanofiber discharged from the nanofiber discharge device is collected while formed in the predetermined shape by the nanofiber collecting mechanism while the nanofiber collecting mechanism is stopped.
  • a nanofiber deposition and formation device of the present invention is a nanofiber deposition and formation device for collecting and depositing nanofiber by a nanofiber collecting mechanism, the nanofiber being discharged from a discharge nozzle of a nanofiber discharge device configured to produce nanofiber by discharging a molten resin or a dissolved resin to a gas flow and drawing in a fiber form with a fine diameter, the nanofiber deposition and formation device including
  • a discharge flow direction deflection mechanism configured to deflect a direction of a discharged nanofiber flow from the discharge nozzle to the nanofiber collecting mechanism.
  • the discharge flow direction deflection mechanism includes an air nozzle configured to deflect the direction of the discharged nanofiber flow by directing deflecting air from a direction of a side of the discharged nanofiber flow in a path from the discharge nozzle to the nanofiber collecting mechanism.
  • the nanofiber deposition and formation device of the present invention includes an air nozzle blasting angle changing mechanism configured to adjust an air blasting angle from the air nozzle.
  • the nanofiber deposition and formation device of the present invention includes an air blast amount changing mechanism configured to adjust an air blast amount of the air nozzle.
  • the air nozzle is provided in plurality and the plurality of air nozzles are concentrically disposed at regular angular intervals to the discharge nozzle.
  • the nanofiber deposition and formation device of the present invention includes an air blast control mechanism configured to continuously control air blasting operation of the air nozzles, concentrically disposed at regular angular intervals, clockwise or counterclockwise in order.
  • a nanofiber deposition and formation method of the present invention is a nanofiber deposition and formation method, using a nanofiber deposition and formation device for collecting and depositing nanofiber by a nanofiber collecting mechanism, the nanofiber being discharged from a discharge nozzle of a nanofiber discharge device configured to produce nanofiber by discharging a molten resin or a dissolved resin to a gas flow and drawing in a fiber form with a fine diameter, wherein
  • a direction of a discharged nanofiber flow is deflected by a discharge flow direction deflection mechanism configured to deflect the direction of the discharge flow from the discharge nozzle to the nanofiber collecting mechanism.
  • the direction of the discharged nanofiber flow is deflected by directing deflecting air from a direction of a side of the discharged nanofiber flow in a path from the discharge nozzle to the nanofiber collecting mechanism.
  • air blasting operation of air nozzles is continuously controlled clockwise or counterclockwise in order.
  • the present invention allows mass production of nanofibers by configuring the nanofiber collecting device to continuously achieve collection and peel off of nanofibers.
  • the present invention also allows construction of a system to efficiently achieve a series of processes until packaging of nanofibers in a predetermined shape by collecting the discharged and supplied nanofibers while forming in the predetermined shape.
  • the nanofiber collecting mechanism of the nanofiber collecting device of the present invention is configured with the groups of collecting bars arranged in parallel, the groups being provided at a predetermined angle at regular intervals to the collecting mechanism rotation axis, to allow mass production of nanofibers by rotating and stopping the collecting mechanism by intermittently driving for each predetermined angle.
  • the nanofiber collecting mechanism is provided with the groups of the collecting bars for collecting nanofibers arranged in parallel, the groups being provided in four directions at a regular angle of 90° to the collecting mechanism rotation axis, to be intermittently rotated and stopped for each 90°.
  • This allows the groups of the collecting bars arranged in the four directions to be consecutively located in the collecting position facing the discharge nozzle of the nanofiber discharge device and the collecting bar group after collection of the nanofibers to be moved to a position out of the collecting position (non-collecting position). Accordingly, such a collecting mechanism allows marked improvement of nanofiber production.
  • the nanofibers collected from the collecting bar group moved to the non-collecting position are peeled off by the peel off mechanism, the nanofibers are attached on a lower surface side of the collecting bar group arranged to be horizontal and thus the nanofiber collecting mechanism allows the nanofibers peeled off from the collecting mechanism by the peel off mechanism to be automatically dropped and accommodated in the recovery container provided below. Accordingly, even nanofibers in a mat shape of a relatively thick layer allow efficient and automatic collection and thus improvement in production efficiency.
  • the present invention allows the direction of the flow of the discharged nanofiber collected and deposited by the nanofiber collecting mechanism to be adjusted and deflected by the discharge flow direction deflection mechanism, and it is thus possible to freely form the nanofibers deposited and formed during collection in a desired predetermined shape, such as a square. Furthermore, regardless of the amount of deposition, it is possible to uniformly deposit the nanofibers on the sprayed surface of the nanofiber collecting mechanism.
  • the air blasting operation of the air nozzle concentrically disposed at regular angular intervals to the discharge nozzle is performed by controlling the air blast (controlling turning on/off or the amount of air) from the respective air nozzles, for example, continuously clockwise or counterclockwise in order or randomly, thereby avoiding many air nozzles to be provided and allowing simplification of the device structure.
  • FIG. 1 is a schematic side view illustrating arrangement relationship between a device for collecting nanofibers as a first embodiment of the present invention and a nanofiber discharge device to discharge and supply nanofibers to the device for collecting nanofibers and illustrates a state of collecting nanofibers while forming in a predetermined shape by a nanofiber collecting mechanism.
  • FIG. 2 is a schematic side view illustrating arrangement relationship of the device for collecting nanofibers as the first embodiment of the present invention and illustrates a state immediately before peeling off a nanofiber formation collected and formed in the predetermined shape by the nanofiber collecting mechanism.
  • FIG. 3 is a schematic side view illustrating arrangement relationship of the device for collecting nanofibers as the first embodiment of the present invention and illustrates a state of peeling off the nanofiber formation collected and formed in the predetermined shape by the nanofiber collecting mechanism.
  • FIG. 4 is a schematic top view illustrating a state of the device for collecting nanofibers as the first embodiment of the present invention taken from above.
  • FIG. 5 is a perspective view illustrating details of the device for collecting nanofibers as the first embodiment of the present invention.
  • FIG. 6 is a schematic side view illustrating a nanofiber deposition and formation device as a second embodiment of the present invention.
  • FIG. 7 is a perspective view illustrating a nanofiber collecting mechanism of the nanofiber deposition and formation device as the second embodiment of the present invention.
  • FIG. 8 is a perspective view illustrating a discharge nozzle configured in a nanofiber discharge device as the second embodiment of the present invention and a discharge flow direction deflection mechanism configured to deflect a discharge flow from the discharge nozzle to the nanofiber collecting mechanism.
  • FIG. 9 is a side view illustrating arrangement relationship between the discharge nozzle configured in the nanofiber discharge device as the second embodiment of the present invention and the discharge flow direction deflection mechanism configured to deflect the discharge flow from the discharge nozzle to the nanofiber collecting mechanism.
  • FIG. 10 is a front view illustrating arrangement relationship between the discharge nozzle configured in the nanofiber discharge device as the second embodiment of the present invention and the discharge flow direction deflection mechanism configured to deflect the discharge flow from the discharge nozzle to the nanofiber collecting mechanism.
  • a nanofiber collecting device 1 in the present embodiment collects nanofibers while forming in a predetermined shape.
  • nanofibers to be a jet may be referred to as a discharge flow
  • the nanofiber discharge device 2 being configured to produce nanofibers by discharging a molten resin or a dissolved resin to a gas flow to draw in the form of fibers with a fine diameter.
  • the nanofibers flow to be a jet from a discharge nozzle 2 A as an outlet of the nanofiber discharge device 2 and collected by a plurality of parallel collecting bars 31 of a collecting bar group 3 as a collecting element configuring a nanofiber collecting mechanism 30 of the nanofiber collecting device 1 .
  • the nanofiber collecting device 1 is provided with a collecting mechanism rotation axis 4 and a peel off mechanism rotation axis 5 provided in parallel at the same height in a frame 9 (details not shown), a collecting mechanism drive motor 6 to rotatively drive the collecting mechanism rotation axis 4 , a peel off mechanism drive motor 7 to rotatively drive the peel off mechanism rotation axis 5 , a control mechanism 8 to stop the collecting mechanism rotation axis 4 for each rotation of 90° and rotate the peel off mechanism rotation axis 5 360° immediately after stopping the collecting mechanism rotation axis 4 . It should be noted that the degree does not have to be 90° and may be a predetermined angle as appropriate.
  • the collecting mechanism rotation axis 4 is arranged horizontally.
  • the collecting mechanism rotation axis 4 is provided with a plurality of collecting bar groups 3 .
  • Each collecting bar group 3 has the parallel collecting bars 31 of a plurality (11) of bars aligned in parallel with each other in an axial direction (in FIG. 4 , aligned in the vertical direction) of the collecting mechanism rotation axis 4 .
  • the number of the parallel collecting bars 31 arranged in parallel is not limited to 11.
  • a fall prevention portion 10 is formed by bending rearward in the direction of rotation.
  • the collecting bar groups 3 are collecting elements attached to the collecting mechanism rotation axis 4 of the nanofiber collecting mechanism 30 .
  • the collecting bar groups 3 as the collecting elements are configured with the parallel collecting bars 31 arranged in parallel.
  • the collecting bar groups 3 of the nanofiber collecting mechanism 30 in the present embodiment are provided in four directions at regular angular intervals (90° intervals) on an outer peripheral surface of the collecting mechanism rotation axis 4 .
  • the nanofiber collecting mechanism 30 does not have to be provided at four spots for each 90° at the collecting mechanism rotation axis 4 and the collecting element may be provided in at least one spot.
  • a stopped position below the collecting mechanism rotation axis 4 is defined as the collecting position and a stopped position behind the collecting mechanism rotation axis 4 (right side in FIGS. 1 through 3 ) is defined as the non-collecting position.
  • the collecting bar group 3 in the collecting position is located on the gas flow, and the collecting bar group 3 in the non-collecting position is located out of the gas flow.
  • the gas flow in the present embodiment flows from the discharge nozzle 2 A illustrated in FIGS. 1 through 3 to the right direction.
  • the 11 parallel collecting bars 31 configuring each collecting bar group 3 include one parallel collecting bar 31 that is located at each end (left and right ends in FIG. 5 ) in the aligned direction and has a shape retaining material 11 fixed thereto, the shape retaining material 11 being formed in a widened U shape overall to retain the shape of the collected nanofiber.
  • the shape retaining materials 11 and the fall prevention portions 10 described earlier prevent nanofibers F collected by the collecting bar groups 3 from falling and sticking out of the collecting bar groups 3 due to the centrifugal force by rotation and the like.
  • the peel off mechanism rotation axis 5 is provided with peel off bars 12 , which are a plurality of bars, as a peel off bar group configuring a peel off mechanism.
  • the peel off bars 12 are bent in a U shape and have both end portions fixed to the peel off mechanism rotation axis 5 .
  • the peel off bars 12 may be configured to allow passing between the parallel collecting bars 31 of the collecting bar groups 3 and does not have to be limited to the U shape.
  • six peel off bars 12 provided at the peel off mechanism rotation axis 5 illustrated in FIG. 4 are aligned in an axial direction (vertical direction in FIG. 4 ) of the peel off mechanism rotation axis 5 , the number may be an appropriate number.
  • the peel off bars 12 pass gaps between the parallel collecting bars 31 aligned in parallel of the collecting bar group 3 in the non-collecting position and peel off the nanofibers F collected and deposited by the collecting bar group 3 (collecting element).
  • a recovery container 13 is placed below the nanofibers F to be peeled off from the parallel collecting bars 31 of the collecting bar group 3 in the non-collecting position and the nanofibers F peeled off from the parallel collecting bars 31 of the collecting bar group 3 in the non-collecting position are thus automatically recovered in the recovery container 13 due to its own weight.
  • the control mechanism 8 stops the rotation drive of the collecting mechanism rotation axis 4 .
  • the “front, rear, top, and bottom” in this context correspond to the “left, right, top, and bottom” in FIGS. 1 through 3 .
  • the collecting bar group 3 in the bottom position is located vertical (state in FIG. 1 ) to the jet of the nanofibers F discharged from the nanofiber discharge device 2 (flow region schematically illustrated by dash double-dotted lines in FIGS. 1 through 3 ).
  • the nanofibers F are discharged and supplied from the discharge nozzle 2 A of the nanofiber discharge device 2 only to the parallel collecting bars 31 in the bottom position of the collecting mechanism rotation axis 4 (collecting bar group 3 in the collecting position). Then, when the parallel collecting bars 31 are in the state of being rotated 90° from there and arranged horizontally (collecting bar group 3 arranged in parallel on the right illustrated in FIG. 2 (collecting element in the non-collecting position)), the peel off mechanism rotation axis 5 is rotated 360°, followed by contact of the peel off bars 12 with the nanofibers F collected by the parallel collecting bars 31 to peel off, as illustrated in FIG. 3 , the nanofibers F collected by the parallel collecting bars 31 . The peeled nanofibers F are then automatically recovered in the recovery container 13 .
  • a series of operations for collecting the nanofibers F by the nanofiber collecting device 1 is described below.
  • the nanofibers F are discharged and supplied from the discharge nozzle 2 A of the nanofiber discharge device 2 to the vertical parallel collecting bars 31 of the collecting bar group 3 in the bottom position (collecting position) of the collecting mechanism rotation axis 4 facing the discharge nozzle 2 A, the nanofibers F are attached on the parallel collecting bars 31 of the collecting bar group 3 in the collecting position to be collected.
  • the nanofibers F are thus deposited in a mat shape in a predetermined relatively thick shape.
  • the control mechanism 8 rotates the collecting mechanism rotation axis 4 90° (as illustrated in FIG. 2 , rotates 90° counterclockwise) and the collecting bar group 3 after collection of the nanofibers F in the collecting position is arranged horizontally in the rear position (non-collecting position). That is, the control mechanism 8 intermittently rotates the collecting mechanism rotation axis 4 to control the collecting mechanism drive motor 6 to move the collecting bar group 3 between the collecting position to collect the nanofibers F and the non-collecting position out of the collecting position. In this state (non-collecting position), as illustrated in FIG. 2 , the collected nanofibers F are arranged on a bottom side (lower surface side) of each parallel collecting bar 31 .
  • the control mechanism 8 rotates the peel off mechanism rotation axis 5 360° (as illustrated in FIG. 2 , counterclockwise), followed by passing of the six peel off bars 12 between the 11 parallel collecting bars 31 , arranged in parallel and having the collected nanofibers F, of the collecting bar group 3 in the non-collecting position (peel off bars 12 illustrated by solid lines in FIG. 3 ).
  • the nanofibers F in the predetermined shape collected by the parallel collecting bars 31 arranged in parallel are thus peeled off by the contact of the peel off bars 12 , and the peeled nanofibers F are automatically accommodated in the recovery container 13 due to its own weight.
  • Such a series of operations is then performed automatically and repeatedly, thereby allowing mass production of the nanofibers F in a mat shape and the like.
  • the method for collecting nanofibers of the present invention includes the following procedure of (a) through (e):
  • nanofibers are discharged from an outlet of a nanofiber discharge device, the device configured to produce nanofibers by discharging a molten resin or a dissolved resin to a hot air flow (hot gas flow) and drawing in the form of fibers with a fine diameter, to a nanofiber collecting mechanism, the collecting mechanism configured by aligning a plurality of bars in parallel and configured to be intermittently rotatively driven in a predetermined direction, on a rear surface side in a direction of rotation of the nanofiber collecting mechanism;
  • a peel off mechanism is rotated to the nanofibers collected and formed in the predetermined shape by the nanofiber collecting mechanism to peel off the nanofibers attached to the nanofiber collecting mechanism;
  • the nanofibers discharged from the nanofiber discharge device is collected while formed in the predetermined shape by the nanofiber collecting mechanism while the nanofiber collecting mechanism is stopped.
  • the collecting mechanism rotation axis 4 configured to be rotatively driven and intermittently rotated and stopped for each 90° is provided with the collecting bar groups 3 in four directions at regular angular intervals of 90° (front, rear, top, and bottom of the collecting mechanism rotation axis 4 ), the collecting bar groups 3 having the parallel collecting bars 31 configured to collect the nanofibers F and aligned in parallel.
  • Such configuration allows the collecting bar groups 3 to be rotated and stopped for each 90° and each of the parallel collecting bars 31 in the four directions to be continually arranged in the position facing the discharge nozzle 2 A of the nanofiber discharge device 2 (collecting position).
  • the intermittent rotation and stop of the collecting mechanism rotation axis 4 is not limited to the control by rotating and stopping for each 90° and is to be intermittently controlled in accordance with the angle of arranging the collecting bar groups 3 as appropriate.
  • the collecting mechanism rotation axis 4 is rotated in a predetermined direction (in FIG. 2 , counterclockwise) to cause the nanofibers F to be attached on the lower surface side of each parallel collecting bar 31 in the non-collecting position.
  • a predetermined direction in FIG. 2 , counterclockwise
  • Such configuration allows the nanofibers F peeled off from the parallel collecting bars 31 arranged in parallel in the non-collecting position by the peel off bars 12 to be automatically dropped and accommodated in the recovery container 13 provided below. It is thus possible to effectively automatically recover nanofibers even in a mat shape of a relatively thick layer and improve the production efficiency.
  • FIG. 6 illustrates a nanofiber deposition and formation device 1 including the nanofiber discharge device 2 and a nanofiber collecting device 15 . Specifically, FIG. 6 illustrates a state where a nanofiber collecting mechanism collects and deposits nanofibers as a discharge flow carried on a gas flow from the discharge nozzle 2 A of the nanofiber discharge device 2 .
  • the device and method for depositing and forming nanofibers of the present invention exhibit strong effects by being applied to the collecting device in the first embodiment, and the present embodiment is described using the discharge nozzle and the collecting device in the first embodiment. It should be noted that the discharge nozzle and the collecting device are not limited to those described in the first embodiment and application to a general technique is readily made by those skilled in the art.
  • the nanofiber deposition and formation device 1 in the present embodiment is roughly provided with the nanofiber discharge device 2 and the nanofiber collecting device 15 .
  • the nanofiber discharge device 2 discharges a molten resin or a dissolved resin to a gas flow and draws the resin in the form of fibers with a fine diameter to produce nanofibers F.
  • the nanofiber discharge device 2 discharges and supplies the nanofibers F as a jet (may be referred to as a discharge flow) carried on a gas flow from the discharge nozzle 2 A to the nanofiber collecting device 15 . As illustrated in FIG.
  • the nanofibers F flow to be a jet from the discharge nozzle 2 A as an outlet of the nanofiber discharge device 2 and are collected by the plurality of parallel collecting bars 31 of the collecting bar groups 3 as collecting elements configuring the nanofiber collecting mechanism 30 of the nanofiber collecting device 15 .
  • the nanofiber collecting device 15 is the nanofiber collecting device 1 described above in the first embodiment.
  • the nanofiber deposition and formation device 1 is provided with the collecting mechanism rotation axis 4 and the peel off mechanism rotation axis 5 provided in parallel at the same height in the frame (housing) 9 , details not shown, a collecting mechanism drive motor configured to rotatively drive the collecting mechanism rotation axis 4 , and a peel off mechanism drive motor configured to rotatively drive the peel off mechanism rotation axis 5 .
  • the collecting mechanism rotation axis 4 is provided with a control mechanism to stop the collecting mechanism rotation axis 4 for each rotation of 90° and to rotate the peel off mechanism rotation axis 5 360° immediately after stopping the collecting mechanism rotation axis 4 .
  • the discharged nanofibers are collected and deposited by the collecting bar group 3 stopped at a bottom position illustrated in FIG. 1 .
  • the nanofibers F deposited and collected by the collecting bar group 3 are peeled off by peel off bars 12 in a U shape attached to the peel off mechanism rotation axis 5 .
  • the collecting mechanism drive motor, the peel off mechanism drive motor, and the control mechanism are omitted from the illustration because they are not the spirit of the present invention.
  • FIG. 7 illustrates details of the nanofiber collecting mechanism 30 .
  • the collecting mechanism rotation axis 4 is provided with the four collecting bar groups 3 arranged at 90° intervals.
  • Each collecting bar groups 3 has the parallel collecting bars 31 of the plurality (11) of bars aligned in the axial direction of the collecting mechanism rotation axis 4 .
  • the fall prevention portion 10 is formed by bending.
  • the 11 parallel collecting bars 31 configuring each collecting bar group 3 include one parallel collecting bar 31 that is located at each end (left and right ends in FIG. 7 ) in the aligned direction and has a shape retaining material 11 fixed thereto in a widened U shape.
  • the shape retaining materials 11 and the fall prevention portions 10 described earlier prevent the nanofibers F collected by the collecting bar groups 3 from falling and sticking out of the collecting bar groups 3 due to the centrifugal force by rotation and the like.
  • the peel off mechanism rotation axis 5 is provided with the peel off bars 12 , which are a plurality of bars, as the peel off bar group configuring the peel off mechanism.
  • the peel off bars 12 are bent in a U shape and have both end portions fixed to the peel off mechanism rotation axis 5 .
  • Six peel off bars 12 provided at the peel off mechanism rotation axis 5 are aligned in the axial direction of the peel off mechanism rotation axis 5 .
  • the peel off bars 12 pass gaps between the parallel collecting bars 31 and peel off the nanofibers F collected and deposited by the parallel collecting bars 31 .
  • the recovery container 13 is placed below the nanofibers F to be peeled off from the parallel collecting bars 31 and the nanofibers F peeled off from the parallel collecting bars 31 are thus automatically recovered in the recovery container 13 due to its own weight.
  • the control mechanism stops the rotation drive of the collecting mechanism rotation axis 4 (state in FIG. 6 ).
  • the “front, rear, top, and bottom” in this context correspond to the “left, right, top, and bottom” in FIG. 6 .
  • the nanofibers F are discharged and supplied from the discharge nozzle 2 A of the nanofiber discharge device 2 only to the parallel collecting bars 31 of the collecting bar group 3 in the bottom position of the collecting mechanism rotation axis 4 (collecting position).
  • the peel off mechanism rotation axis 5 is rotated 360°, followed by contact of the peel off bars 12 with the nanofibers F collected by the parallel collecting bars 31 to peel off the nanofibers F collected by the parallel collecting bars 31 .
  • the peeled nanofibers F are then automatically recovered in the recovery container 13 .
  • a discharge flow direction deflection mechanism 16 is described below that is configured to deflect a flow of the discharged nanofibers F (discharge flow) from the discharge nozzle 2 A of the nanofiber discharge device 2 to the nanofiber collecting mechanism 30 carried on a gas flow. It should be noted that, although the discharge flow direction deflection mechanism 16 in the present embodiment belongs to the nanofiber discharge device 2 , it may belong to the nanofiber collecting device 15 side.
  • the discharge flow direction deflection mechanism 16 deflects a flow of the discharged nanofibers F by directing deflecting air from a direction of a side of the flow of the discharged nanofibers F from the discharge nozzle 2 A to form a discharge flow to a desired direction, in other words, to shift the flow of the discharged nanofibers F.
  • the discharge flow direction deflection mechanism 16 is provided with a plurality of air nozzles 17 to direct the deflecting air from the side to the flow of the discharged nanofibers F from the discharge nozzle 2 A.
  • the plurality of air nozzles 17 are arranged circumferentially.
  • the deflecting air blasted from the air nozzles 17 is blown at respective angles (air blasting angles to the discharge flow) adjustable by deflection angle adjustment plates 18 .
  • the deflection angle adjustment plates 18 are radially (direction to move closer to or farther from the flow of the discharged nanofibers F) slidably mounted on a retention frame 19 in a hollow disk shape.
  • pipes are connected to supply high pressure air to be the deflecting air while the pipes are now shown for simplification of the drawing. The pipes may guide the deflecting air to the air nozzles 17 .
  • the air nozzles 17 are provided with a pump, a solenoid valve for operation of turning on/off air supply, and the like while they may be configured as appropriate and details are not described herein.
  • This embodiment of the present invention is provided with an air blast control mechanism 21 configured to control various types of air blasting operation including air blast timing by each air nozzle 17 and an air blast amount changing mechanism 20 configured to electrically adjust an air blast amount by each air nozzle 17 .
  • the retention frame 19 in a hollow disk shape on which the plurality of air nozzles 17 are circumferentially mounted is concentrically arranged to surround the discharge nozzle 2 A on a downstream side of the discharge nozzle 2 A and is configured integrally with the nanofiber discharge device 2 via a coupling frame, not shown.
  • eight of the air nozzles 17 are disposed at regular angular intervals (45° intervals) concentrically centered around the arrangement of the discharge nozzle 2 A.
  • the plurality of air nozzles 17 are not limited to the arrangement of eight nozzles at 45° intervals.
  • each air nozzle 17 is mounted via the deflection angle adjustment plate 18 .
  • the deflection angle adjustment plates 18 are slidably mounted on the retention frame 19 in a hollow disk shape to allow oscillation in a direction to move closer to or farther from the flow of the discharged nanofibers F.
  • the deflection angle adjustment plates 18 are air nozzle blasting angle changing mechanisms configured to adjust the air blasting angles from the air nozzles 17 .
  • a nanofiber deposition and formation method of the present invention uses a nanofiber deposition and formation device for collecting and depositing nanofibers by a nanofiber collecting mechanism, the nanofibers being discharged from a discharge nozzle of a nanofiber discharge device configured to produce nanofibers by discharging a molten resin or a dissolved resin to a gas flow and drawing in a fiber form with a fine diameter, wherein
  • a discharged nanofiber flow from the discharge nozzle to the nanofiber collecting mechanism is deflected by the discharge flow direction deflection mechanism 16 to change a position to deposit the nanofibers and obtain a nanofiber deposition in a desired predetermined shape.
  • the discharge flow direction deflection mechanism 16 directs deflecting air from a direction of a side of the discharged nanofiber flow in a path from the discharge nozzle to the nanofiber collecting mechanism to deflect the direction of the discharged nanofiber flow.
  • the discharge flow direction deflection mechanism 16 controls air blasting operation of the air nozzles concentrically disposed at regular angular intervals to blast the air, for example, continuously controlled clockwise or counterclockwise in order or randomly.
  • the air blast control in this case may be control of turning on/off the air blast by each air nozzle or control of an air blast amount. This allows the deflecting air to be generated as if the deflecting air moves around the discharged nanofiber flow and the direction of the discharge flow to be randomly changed. It is thus possible to form a nanofiber formation in a predetermined shape.
  • the direction of the flow of discharged nanofibers collected and deposited by the nanofiber collecting mechanism is appropriately adjusted by the discharge flow direction deflection mechanism 16 in accordance with a shape to be formed.
  • a shape to be formed Such configuration allows the nanofibers F collected and deposited by the nanofiber collecting mechanism to be freely deposited and formed in a predetermined shape, such as a square shape. It is thus possible to form a formation in a predetermined shape including a sheet shape, a mat shape, and a block shape. It is also possible to uniformly deposit the nanofibers F on the sprayed surface of the parallel collecting bars 31 of the collecting bar groups 3 regardless of the amount of deposition.
  • the position to deposit the nanofibers F to be deposited by the collecting mechanism is allowed to be freely controlled by adjusting the air blasting angle and the air blast amount of each air nozzle 17 , and it is thus possible to prepare a sheet of the nanofibers F in a shape with a high degree of freedom without limited by the type of collecting mechanism.
  • the air blast control mechanism 21 is capable of controlling the operation of turning on/off the air blast from air nozzles 17 concentrically disposed at regular angular intervals so as to, for example, continuously rotate clockwise or counterclockwise in order or randomly, thereby avoiding many air nozzles to be provided and achieving simplification of the device structure.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Nonwoven Fabrics (AREA)
US16/644,681 2017-09-05 2018-09-04 Nanofiber collection device, nanofiber collection method, and nanofiber accumulation/molding apparatus and accumulation/molding method therefor Abandoned US20210025081A1 (en)

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JP2017-170641 2017-09-05
JP2017170641A JP2019044307A (ja) 2017-09-05 2017-09-05 ナノファイバーの捕集装置及びナノファイバーの捕集方法
JP2017194709A JP6517900B2 (ja) 2017-10-04 2017-10-04 ナノファイバーの堆積・成形装置及びその堆積・成形方法
JP2017-194709 2017-10-04
PCT/JP2018/032786 WO2019049866A1 (fr) 2017-09-05 2018-09-04 Dispositif de collecte de nanofibres, procédé de collecte de nanofibres, et appareil d'accumulation/moulage de nanofibres et son procédé d'accumulation/moulage

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US11015267B2 (en) * 2015-04-23 2021-05-25 Rowan University System and method for electrospun fiber straining and collecting

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CA3112231A1 (fr) 2019-03-14
WO2019049866A1 (fr) 2019-03-14
KR20200091851A (ko) 2020-07-31
EP3680370A1 (fr) 2020-07-15
SG11202105961VA (en) 2021-07-29
TW201923175A (zh) 2019-06-16
CN111954731A (zh) 2020-11-17

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