Abstract:
The present invention is a method for manufacturing cleaning members obtained by cutting multi-layer webs formed by: spreading fiber bundles, the lengthwise directions of which are parallel to the direction in which said fiber bundles are conveyed; and layering together at least the spread fiber bundles and non-woven fabric strips. Said method includes a step in which, before spreading, two or more fiber bundles are joined together, forming one or more join sections. Said joins are performed by joining the back end (with respect to the conveyance direction) of one fiber bundle to the front end (with respect to the conveyance direction) of the next fiber bundle.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a method of producing a cleaning member, and a system of producing a cleaning member. 
       BACKGROUND ART 
       [0002]    Various types of cleaning members capable of trapping dust, trash, etc., are conventionally known, and methods for producing the various types have been examined from a variety of viewpoints. 
         [0003]    For example, Patent Literature 1 proposes a method of producing a cleaning member comprising the steps of: 
         [0004]    stacking a belt-shaped inner fibrous layer consisting of continuous fiber bundles and a belt-shaped sheet member, both being partially joined to form a first continuous body, followed by the formation of a second continuous body in a similar manner, and, after the first and the second continuous bodies are stacked and partially fixed, stacking and fixing a belt-shaped outer fibrous layer consisting of continuous fiber bundles on each of the inner fibrous layer side of the first and the second continuous bodies; 
         [0005]    cutting the laminate obtained in the preceding step into a predetermined length; and 
         [0006]    applying a compressed air to the fibrous layer part of the cut laminate to open the fiber bundles; 
         [0007]    wherein the belt-shaped inner fibrous layer and outer fibrous layer are each composed of fiber bundles consisting of curled fibers bent in a zig-zag form, a vertical height between the alternating peaks and troughs of the above curled fiber is 0.1 to 0.7 mm, and, during the step of opening the above fiber bundles, the fiber bundles in the cut laminate are teased so that the entire periphery of the cleaning member is covered with brush tips consisting of the fiber of the fiber bundles. 
         [0008]    Also, Patent Literature 2, for example, proposes a method of producing a cleaning member, wherein 
         [0009]    a first continuous body having a first fibrous layer consisting of continuous fiber bundles and a first belt-shaped member, in which both longitudinal ends of the first belt-shaped member are folded to be stacked and fixed, and the first fibrous layer is stacked on and fixed to the outer face side of the first belt-shaped member, and a second continuous body having a second fibrous layer consisting of continuous fiber bundles and a second belt-shaped member, in which both longitudinal ends of the second belt-shaped member are folded to be stacked and fixed, and the second fibrous layer is stacked and fixed onto the outer face side of the second belt-shaped member, are produced, and after the first continuous body and the second continuous body thus produced are stacked and joined to each other, a third fibrous layer and a fourth fibrous layer, each consisting of continuous fibrous bundles, are stacked on the first fibrous layer and the second fibrous layer, respectively, and fixed to form a laminate, then the laminate thus formed is cut to obtain individual cleaning members, 
         [0010]    characterized in that the method comprises the steps of: 
         [0011]    intermittently forming broken guide lines spanning the entire lateral area of each of the first belt-shaped member and the second belt-shaped member in the first belt-shaped member and the second belt-shaped member so that a central part sandwiched by a pair of broken guide lines and an external part provided consecutively in the central part via the broken guide lines are formed in each of the first belt-shaped member and the second belt-shaped member, respectively; 
         [0012]    joining the first belt-shaped member and the second belt-shaped member, after forming the broken guide lines, to the first fibrous layer and the second fibrous layer with a central continuous seal line spanning the entire lateral area of each of the first fibrous layer and the second fibrous layer to produce the first continuous body and the second continuous body; 
         [0013]    stacking the first continuous body and the second continuous body to join them with side noncontinuous seals spanning the entire lateral area of the first fibrous layer and the second fibrous layer; 
         [0014]    further stacking and fixing a third fibrous layer and a fourth fibrous layer onto the first fibrous layer of the first continuous body and the second fibrous layer of the second continuous body to form the laminate; 
         [0015]    excising the external part flanking the central part, leaving the central part sandwiched by the pair of broken guide lines, from each of the cut first belt-shaped member and the cut second belt-shaped member, after cutting the laminate; and 
         [0016]    opening the cut first through fourth fibrous layers, so as to tease them randomly in three-dimensional directions, after cutting the laminate. 
         [0017]    Furthermore, Patent Literature 3, for example, proposes a method of producing a cleaning member comprising the steps of: 
         [0018]    laminating a continuous body comprising a four-layered long fibrous layer in which fiber bundles are oriented in one direction, a continuous body comprising two long scraping sheets, and a continuous body comprising two long base sheet in the order of the continuous body comprising the fibrous layer, the continuous body comprising the scraping sheets, the continuous body comprising the fibrous layer, the continuous body comprising the two base sheets, the continuous body comprising the fibrous layer, the continuous body comprising the scraping sheets, and the continuous body comprising the fibrous layer, 
         [0019]    joining the continuous bodies with one another at a predetermined distance in the lateral direction to prepare a cleaning member continuous body, and then 
         [0020]    cutting, in the lateral direction, the cleaning member continuous body at the junctions between the continuous body of the fibrous layer and the continuous body of the base sheet and the continuous body of the scraping sheet to obtain a plurality of the cleaning member. 
       CITATION LIST 
     Patent Literature 
       [0021]    [PTL 1] Japanese Patent No. 4878988 
         [0022]    [PTL 2] Japanese Patent No. 4738311 
         [0023]    [PTL 3] Japanese Patent No. 4675218 
       SUMMARY OF INVENTION 
     Technical Problem 
       [0024]    However, there is currently a need for a novel production method and a production system of producing cleaning members capable of trapping dust, trash, etc., in a more efficient manner. Considering the above circumstance, the present invention was found by the present inventors as a result of intensive and extensive investigation. 
         [0025]    Thus, it is an object of the present invention to provide a novel production method and a novel production system that are suitable for producing a cleaning member having excellent cleaning performance and that realize efficient production, in particular, that can continuously produce a cleaning member. 
       Solution to Problem 
       [0026]    In order to achieve the above objective, the present invention provides a method of producing a cleaning member obtained by cutting a multi-layer web formed by opening fiber bundles that are elongated in a conveyance direction and laminating at least the opened fiber bundles and a belt-shaped nonwoven fabric, wherein the method of producing the cleaning member comprises at least a step of connecting at least two of the fiber bundles prior to opening to form a connecting part, the step comprising connecting the terminal end in the conveyance direction of a preceding fiber bundle and the starting end in the conveyance direction of the following fiber bundle to form the connecting part. 
         [0027]    In order to achieve the above objective, the present invention further provides a system of producing a cleaning member obtained by cutting a multi-layer web formed by opening fiber bundles that are elongated in a conveyance direction and laminating at least the opened fiber bundles and a belt-shaped nonwoven fabric, wherein the system of producing a cleaning member comprises at least a device for connecting at least two of the fiber bundles prior to opening, the device connecting the terminal end in the conveyance direction of a preceding fiber bundle and the starting end in the conveyance direction of the following fiber bundle to form a connecting part. 
       Effects of Invention 
       [0028]    In accordance with the present invention, a novel production method and a novel production system that are suitable for producing a cleaning member having an excellent cleaning performance, that realize efficient production, and in particular, that can continuously produce a cleaning member by connecting at least two fiber bundles is provided. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0029]      FIG. 1  is a perspective view of a cleaning member produced by an embodiment of the production method and production system of the present invention and a holding tool that is fixed to the cleaning member. 
           [0030]      FIG. 2  is a sectional view of  FIG. 1  along a X-X line. 
           [0031]      FIG. 3  is a plan view of the cleaning member shown in  FIG. 1 . 
           [0032]      FIG. 4  is a schematic view for explaining a method and a system of producing the cleaning member shown in  FIG. 1 . 
           [0033]      FIG. 5  is a view that illustrates an embodiment of the production method and the production system of the present invention. 
           [0034]      FIG. 6  is a view that schematically illustrates a connecting part of fiber bundles. 
           [0035]      FIG. 7  is a schematic view that explains an embodiment of a step of detecting a connecting part of fiber bundles by a detecting unit and a device that comprises the detecting unit. 
           [0036]      FIG. 8  is a schematic view that explains an embodiment of a step of detecting a connecting part of fiber bundles by a detecting unit and a device that comprises the detecting unit. 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
     (Method of Producing a Cleaning Member) 
       [0037]    The method of producing the cleaning member of the present invention will now be explained in detail below. 
         [0038]    The method of producing a cleaning member according to the present invention is a method of producing a cleaning member obtained by cutting a multi-layer web formed by opening fiber bundles that are elongated in a conveyance direction and laminating at least the opened fiber bundles and a belt-shaped nonwoven fabric, the method comprising at least a step of connecting at least two of the fiber bundles prior to opening to form a connecting part, the step comprising connecting the terminal end in the conveyance direction of a preceding fiber bundle and the starting end in the conveyance direction of the following fiber bundle to form the connecting part (an aspect 1). 
         [0039]    The method of producing a cleaning member according to the present invention is a novel production method that is suitable for producing a cleaning member having excellent cleaning performance and that can realize efficient production. In particular, in the method of producing a cleaning member according to the present invention, when a preceding fiber bundle is used up, and then the following fiber bundle is fed to the production system, the terminal end in the conveyance direction of the preceding fiber bundle is connected to the starting end in the conveyance direction of the following fiber bundle. This allows continuous feeding of fiber bundles to the production system, and thus allows efficient production of cleaning members without stopping production of the cleaning members. It should be noted that the term “fiber bundles prior to opening” used herein means that the step of opening such fiber bundles is carried out later and does not mean that the fiber bundles to be connected are not opened before the bundles are connected. 
         [0040]    It is preferred to further include a step of opening the fiber bundles after the step of forming the connecting part and before laminating the fiber bundles and the belt-shaped nonwoven fabric in the aspect 1 (an aspect 2). According to the aspect 2, since the fiber bundles are opened after connecting the preceding and the following fiber bundles, and thus the connecting part of the fiber bundles is securely connected so that the connecting part is not opened, while the parts other than the connecting part are opened, and thus the width of the parts can be increased to a width that corresponds to the required dimension as the cleaning member. 
         [0041]    It is preferred to further include a step of detecting the connecting part by a detecting unit after the step of opening the fiber bundles and before laminating the fiber bundles and the belt-shaped nonwoven fabric in the aspect 2 (an aspect 3). According to the aspect 3, the connecting part of the fiber bundles can be detected by the detecting unit by determining, for example, the width, thickness, hardness, etc., of the connecting part. 
         [0042]    More preferably, the detecting unit in the aspect 3 detects the connecting part by detecting that the length in the lateral direction of the fiber bundles is smaller than a predetermined length (an aspect 4). According to the aspect 4, the connecting part of the fiber bundles are securely connected and thus is not opened as described above, and then the width of the fiber bundles in the connecting part are not substantially widened. As a result, the detecting unit that determine the width of the fiber bundles can detect that the connecting part of the fiber bundles, the part not having a width that corresponds to the required dimension as the cleaning member, passes under the detecting unit. The term “predetermined length” used herein refers to a length that is less than a width that corresponds to the required dimension as the cleaning member, that is sufficiently larger than the width of the connecting part of the fiber bundles, the part being not opened and thus being not widened as described above, and that is appropriately selected considering the detection accuracy. Preferably, the detecting unit is disposed before the step of laminating the fiber bundles and a belt-shaped nonwoven fabric to form the multi-layer web as described below. Examples of the detecting unit include, for example, phototubes and cameras. As used herein, the phototubes are a detector in which a light-emitting part and a light-receiving part are integrated, the detector comprising the light-emitting part that emits light rays such as infrared rays to a predetermined lateral position of the fiber bundles and the light-receiving part detecting the reflected light. By such configuration, depending upon whether the light-receiving part detects the reflection of light rays from the light-emitting part, the position of the connecting part of the fiber bundles, the part having a smaller width, is detected. The cameras, as used herein, by binarizing an image taken with the cameras using a predetermined parameter and determining whether the fiber bundles are widened to a predetermined lateral position, is for detecting the position of the connecting part of the fiber bundles, the part having a smaller width. 
         [0043]    It is preferred to further include a step of laminating the fiber bundles and a belt-shaped nonwoven fabric to form a multi-layer web and a step of fixing the fiber bundles and the belt-shaped nonwoven fabric contained in the multi-layer web to each other after the step of opening the fiber bundles, in any one of the aspects 2-4 (an aspect 5). 
         [0044]    Preferably, the fixing step in the aspect 5 is a step of melt-bonding the fiber bundles and the belt-shaped nonwoven fabric contained in the multi-layer web to each other (an aspect 6). This step allows secure fixing of the fiber bundles and the belt-shaped nonwoven fabric to each other and excels in high-speed production. In another embodiment, the fixing step is a step of adhering, by hot-melt, the fiber bundles and the belt-shaped nonwoven fabric contained in the multi-layer web to each other. 
         [0045]    It is preferred to further include a step of cutting the multi-layer web in the lateral direction of the multi-layer web to form individual cleaning members and a step of ejecting any of the cleaning members that include the connecting part of the fiber bundles after the fixing step, in the aspect 5 or 6 (an aspect 7). Since the connecting part of the fiber bundles is securely connected, and thus the fiber bundles are not opened, any of the cleaning members that include the connecting part of the fiber bundles is inferior in quality. According to the aspect 7, such a low-quality cleaning member can be ejected, and thus higher-quality cleaning members can be produced, which is advantageous. 
         [0046]    In the method of producing a cleaning member according to the present invention, two or more of the aspects 1-7 can be combined. 
       [System of Producing a Cleaning Member] 
       [0047]    The system of producing a cleaning member according to the present invention will now be explained in detail below. 
         [0048]    The system of producing a cleaning member according to the present invention is a system of producing a cleaning member obtained by cutting a multi-layer web formed by opening fiber bundles that are elongated in a conveyance direction and laminating the opened fiber bundles and a belt-shaped nonwoven fabric, and comprises at least a device for connecting at least two fiber bundles, the device connecting the terminal end in the conveyance direction of a preceding fiber bundle and the starting end in the conveyance direction of the following fiber bundle to form a connecting part (an aspect 8). 
         [0049]    The system of producing a cleaning member according to the present invention is a novel production system that is suitable for producing a cleaning member having an excellent cleaning performance and that realizes efficient production. In particular, when a preceding fiber bundle is used up, and then the following fiber bundle is fed to the production system, the system of producing a cleaning member according to the present invention connects the terminal end in the conveyance direction of the preceding fiber bundle to the starting end in the conveyance direction of the following fiber bundle. This allows continuous feeding of fiber bundles to the production system, and thus allows efficient production of cleaning members without stopping production of the cleaning members. 
         [0050]    Preferably, the system in the aspect 8 further comprises a device for opening the fiber bundles having the connecting part (an aspect 9). According to the aspect 9, since the fiber bundles are opened after forming the connecting part in the fiber bundles, the connecting part of the fiber bundles is securely connected and thus the fiber bundles in the part are not opened, while the parts other than the connecting part are opened and thus the width of the parts is increased to a width that corresponds to the required dimension as the cleaning member. 
         [0051]    Preferably, the system in the aspect 9 further comprises a device that comprises a detecting unit that detects the connecting part before laminating the opened fiber bundles and a belt-shaped nonwoven fabric (an aspect 10). According to the aspect 10, the connecting part of the fiber bundles can be detect by the detecting unit by, for example, determining the width, thickness, hardness, etc., of the connecting part. 
         [0052]    More preferably, the detecting unit in the aspect 10 detects the connecting part by detecting that the length in the lateral direction of the fiber bundle is smaller than a predetermined length (an aspect 11). According to the aspect 11, the connecting part of the fiber bundles is securely connected and thus is not opened as described above, and then the width of the fiber bundles in the connecting part are not substantially widened. As a result, the detecting unit that determines the width of the fiber bundles can detect that the connecting part of the fiber bundles, the part not having a width that corresponds to the required dimension of the cleaning member, passes under the detecting unit. Preferably, the detecting unit is disposed before the step of laminating the fiber bundles and a belt-shaped nonwoven fabric to form a multi-layer web as described below. Examples of the detecting unit include, for example, phototubes and cameras. As used herein, the phototubes are a detector in which a light-emitting part and a light-receiving part are integrated, the detector comprising the light-emitting part that emits light rays such as infrared rays to a predetermined lateral position of the fiber bundles and the light-receiving part detecting the reflected light. By such configuration, depending upon whether the light-receiving part detects the reflection of light rays from the light-emitting part, the position of the connecting part of the fiber bundles, the part having a smaller width, is detected. The cameras, as used herein, by binarizing an image taken with the cameras using a predetermined parameter and determining whether the fiber bundles are widened to a predetermined lateral position, is for detecting the position of the connecting part of the fiber bundles, the part having a smaller width. 
         [0053]    More preferably, the system in any one of the aspects 9-11 further comprises a device for laminating the opened fiber bundles and a belt-shaped nonwoven fabric to form a multi-layer web and a device for melt-bonding the fiber bundles and the belt-shaped nonwoven fabric contained in the multi-layer web to each other (an aspect 12). 
         [0054]    More preferably, the system in the aspect 12 further comprises a device for cutting the melt-bonded multi-layer web in the lateral direction of the multi-layer web to form individual cleaning members and a device for ejecting any of the cleaning members that include the connecting part of the fiber bundles (an aspect 13). Since the connecting part of the fiber bundles is securely connected and thus the fiber bundles are not opened, a cleaning member that comprises the connecting part of the fiber bundles is inferior in quality. According to the aspect 13, such low-quality cleaning member can be ejected, and thus higher-quality cleaning members can be produced, which is advantageous. 
         [0055]    In the system of producing a cleaning member according to the present invention, two or more of the aspects 8-13 can be combined. 
         [0056]    Embodiments of the method and the system of producing a cleaning member according to the present invention are described in more detail with reference to  FIGS. 1-8 . The method and the system of producing a cleaning member according to the present invention are not limited to the embodiments of the present invention represented by  FIGS. 1-8  without departing from the scope and the spirit of the present invention. 
         [0057]    First, a cleaning member  1  will be explained with reference to  FIG. 1  through  FIG. 3 . 
         [0058]      FIG. 1  is a perspective view of a holding tool that is fixed to the cleaning member  1 ,  FIG. 2  is a sectional view of  FIG. 1  along the X-X line, and  FIG. 3  is a plan view of the cleaning member  1  shown in  FIG. 1 . In the explanation below, while “top” may be referred to as an upper side and “bottom” as a downside in  FIG. 2 , “top” and “bottom” in  FIG. 2  are only used for the sake of explanation, and do not intend to limit the actual upper or lower direction of the cleaning member  1 . 
         [0059]    As shown in  FIG. 1  through  FIG. 3 , the cleaning member  1  is equipped with a brush sheet  2 , a base sheet  12  stacked on the upper side of the brush sheet  2 , and a holding sheet  13  stacked on the upper side of the base sheet  12 . 
         [0060]    As shown in  FIG. 1  through  FIG. 3 , in the cleaning member  1 , a receiving part  14  into which the insertion part  16  of a holding tool  15  is to be inserted has been formed in between the base sheet  12  and the holding sheet  13 . As shown in  FIG. 1  through  FIG. 3 , in the cleaning member  1 , two receiving parts  14  have been formed so as to receive the insertion part  16  that was divided into two. While the number of the receiving parts  14  in this embodiment is two, the number of the receiving parts can be changed as appropriate depending on the number of divisions of the insertion part  16 . In another embodiment, there may be mentioned an embodiment in which the number of the insertion parts  14  is three or more. 
         [0061]    As shown in  FIG. 2 , the brush sheet  2  has a fibrous member of a four-layer structure comprising a first fibrous member  3 , a second fibrous member  4  stacked at the downside of the first fibrous member  3 , a third fibrous member  5  stacked at the downside of the second fibrous member  4 , and a fourth fibrous member  6  stacked at the downside of the third fibrous member  5 , and a sheet with slits  7  stacked at the downside of the four-layer structured fibrous member (at the downside of the fourth fibrous member  6 ). The fibrous member of the brush sheet  2  according to the present embodiment has a four-layer structure, but the layer structure of the fibrous member can be changed as appropriate. In another embodiment, there may be mentioned an embodiment in which the fibrous member has a one-layer structure, a two-layer structure or a three-layer structure, and in still another embodiment, the fibrous member has a structure of five-layer or more. Also, while the brush sheet  2  in the present embodiment has a sheet with slits  7 , the presence or absence of the sheet with slits  7  may be selected as appropriate. In another embodiment, the sheet with slits  7  has been omitted. 
         [0062]    The first through fourth fibrous members  3  through  6  are fiber bundles to which an oil solution is attached, and thus is a dust adhering agent (for example, an oil solution comprising liquid paraffin as an active ingredient) having an effect of promoting the adherence of dust, trash, etc. 
         [0063]    A fiber bundle is, for example, a tow, preferably an opened tow. As described in JIS L 0204-3:1998, 3.1.24, “tow” indicates a bundle of an extremely large number of filaments. 
         [0064]    A fiber bundle may be a bundle of slit fibers (fibers made by cutting a film into reed-shaped part and then stretching them), split fiber (fibers made by subdividing reed-shaped parts of film into a network structure), etc. 
         [0065]    As fiber bundles, there can be mentioned, for example, fiber bundles consisting of or comprising thermoplastic fibers, etc. As raw materials constituting fiber bundles, there can be mentioned, for example, polyethylene, polypropylene, polyethylene terephthalate, nylon, rayon, etc., and the type of fibers constituting fiber bundles include, for example, single fibers, composite fibers (for example, core-in-sheath composite fibers, side-by-side composite fibers), etc. From the viewpoint of thermal bondability, composite fibers may preferably be core-sheath type composite fibers, and more preferably core-sheath type composite fibers in which the melting point of the core is higher than that of the sheath. 
         [0066]    As a preferred core-in-sheath composite fiber, there can be mentioned core-sheath type composite fibers in which the core consists of polypropylene or polyethylene terephthalate and the sheath consists of polyethylene, and more preferably core-sheath type composite fibers in which the core consists of polyethylene terephthalate and the sheath consists of polyethylene. 
         [0067]    The purity of a fiber constituting fiber bundles may preferably be 1-500 dtex, more preferably 2-10 dtex. Fiber bundles may comprise a plurality of fibers having the same purity, or a single fiber or a plurality of fibers having a different purity. 
         [0068]    In the present embodiment, each fiber constituting fiber bundles is composed of curled fibers. By allowing each fiber to be composed of curled fibers, fiber bundles can be made bulky and can be made a structure that permits easy trapping of dust etc. at the curled parts. In another embodiment, there can be mentioned an embodiment in which each fiber constituting fiber bundles is composed of noncurled fibers. 
         [0069]    Similarly to the base sheet  12  and the holding sheet  13 , as described below, the sheet with slits  7  is composed of a nonwoven fabric consisting of a thermoplastic fiber (a thermally fusion-bondable fiber) or a nonwoven fabric comprising a thermoplastic fiber, and is formed in a rectangular shape of the same width and the same length as those of the base sheet  12 . In the sheet with slits  7 , saw-edged cuts (not shown) are made at a given distance along the entire sheet with slits  7 , and with the cuts, saw-edged reed-shaped parts (not shown) are formed over the entire length along both lateral ends of the sheet with slits  7 . 
         [0070]    As shown in  FIG. 1  through  FIG. 3 , a base sheet  12  and a holding sheet  13  are stacked sequentially on the upper side of the first fibrous member  3  of the brush sheet  2 , and a receiving part  14  into which the insertion part  16  of the holding tool  15  is to be inserted is formed in between the base sheet  12  and the holding sheet  13 . 
         [0071]    As shown in  FIG. 3 , the base sheet  12  and the holding sheet  13  have a rectangular form, and the lateral dimension (the direction of left to right in  FIG. 3 ) of both sheets is set to be the same, and the longitudinal dimension (the vertical direction in  FIG. 3 ) is set to be longer in the base sheet  12  so that both longitudinal ends of the base sheet  12  protrudes by a predetermined length from both longitudinal ends of the holding sheet  13 , with the holding sheet  13  being stacked on the upper side of the base sheet  12 . 
         [0072]    The base sheet  12  and the holding sheet  13  are made of a nonwoven fabric consisting of a thermoplastic fiber (thermally fusion-bondable fiber) or a nonwoven fabric comprising a thermoplastic fiber. As thermoplastic fibers, for example, a polyethylene fiber, a polypropylene fiber, a polyethylene terephthalate fiber, a composite fiber of polyethylene and polyethylene terephthalate, and a composite fiber of polyethylene and polypropylene, such as core-sheath type composite fibers in which the core is composed of polyethylene terephthalate and the sheath is composed of polyethylene can be mentioned. As the type of nonwoven fabric, for example, a thermal bond nonwoven fabric, a spunbonded nonwoven fabric, a spunlace nonwoven fabric and the like can be mentioned. 
         [0073]    In another embodiment, there can be mentioned an embodiment in which the base sheet and the holding sheet are made of a thermoplastic resin film such as a polyethylene film and a polypropylene film, and in still another embodiment, the base sheet and the holding sheet are made of a laminate sheet comprising a nonwoven fabric and a resin film. 
         [0074]    The base sheet  12  and the holding sheet  13  are integrally fusion-bonded to all the layers (the first fibrous member  3 , the second fibrous member  4 , the third fibrous member  5 , the fourth fibrous member  6 , and the sheet with slits  7 ) of the brush sheet  2  through a first melt bonded part forming device  158  described below, and in the cleaning member  1 , a first melt-bonding part  8  longitudinally extending in the central part is formed as shown in  FIG. 1  through  FIG. 3 . Furthermore, at both ends (lateral ends in  FIG. 2 ) of the first melt-bonding part  8 , the base sheet  12  and the holding sheet  13  are integrally bonded to one layer (the first fibrous member  3 ) of the brush sheet  2  through a second melt bonded part forming device  134  described below, and in the cleaning member  1 , two second melt-bonding parts  11  that melt-bond the first fibrous member  3 , the base sheet  12 , and the holding sheet  13  together are longitudinally formed. Each of the two second melt-bonding parts  11  is intermittently formed. Since the first fibrous member  3  is fusion-bonded to the base sheet  12  and the holding sheet  13  so that the first fibrous member  3  is more likely to follow the movement of these sheets  12  and  13  compared with the other fibrous members  4 ,  5  and  6 , the brush sheet  2  tends to further expand during use, resulting in an improved cleaning efficiency. 
         [0075]    The base sheet  12  and the holding sheet  13  are fusion-bonded to all the layers (the first fibrous member  3 , the second fibrous member  4 , the third fibrous member  5 , the fourth fibrous member  6 , and the sheet with slits  7 ) of the brush sheet  2  in the first melt-bonding part  8 , and are fusion-bonded to the first fibrous member  3  of the brush sheet  2  in two second melt-bonding parts  11 . This results in the formation of a pair of receiving parts  14 , which extends in the longitudinal direction of the base sheet  12  and the holding sheet  13  and which is a saclike space opening on both longitudinal ends, compartmentalized by the first melt-bonding part  8  and two second melt-bonding parts  11 , thereby enabling the insertion part  16  of the holding tool  15  to be inserted into the receiving part  14 . 
         [0076]    The base sheet  12  and the holding sheet  13  are fusion-bonded to the first fibrous member  3  of the brush sheet  2  at the central part thereof through a second melt bonded part forming device  134  described below, and in the cleaning member  1 , a pair of melt-bonding lines  18  are formed at a predetermined distance in the lateral direction of the base sheet  12  and the holding sheet  13 , as shown in  FIG. 3 , with a first melt-bonding part  8  being formed in between the pair of melt-bonding lines  18 . The pair of melt-bonding lines  18  are a landmark for monitoring the position of the first melt-bonding part  8  during the production step, and by monitoring whether the first melt-bonding part  8  is disposed in between the pair of the thermal melt-bonding lines  18  with a sensor etc., good items and defective items can be sorted out. 
         [0077]    As shown in  FIG. 1  through  FIG. 3 , two second melt-bonding parts  11  are intermittently provided at several places in the longitudinal direction of the base sheet  12  and the holding sheet  13 , and by engaging an arc-like protrusion  16   a  at each insertion part  16  of the holding tool  15  with the non-fusion-bonded part of the two second melt-bonding parts  11 , each insertion part  16  of the holding tool  15  is prevented from coming off each receiving part  14 . 
         [0078]    As shown in  FIG. 1 , saw-edged slits  20   a  are provided at each given distance along the longitudinal direction in both lateral ends (the external parts of two second melt-bonding parts  11 ) of the base sheet  12  and the holding sheet  13 , and with the slits  20   a , a plurality of reed-shaped parts  20 , both ends of which are saw-edged, are provided. In another embodiment, there can be mentioned an embodiment in which no saw-edged slits  20   a  are provided in the base sheet  12  and the holding sheet  13 , and thus reed-shaped parts  20  are not provided. 
         [0079]    As shown in  FIG. 1 , the holding tool  15  has a pair of rectangular plate-shaped insertion parts  16  disposed in parallel to each other, a pair of arc-like protrusions  16   a  in each of the insertion parts  16 , the protrusions being longitudinally separated from each other and protruding from the outer face of both longitudinal ends of each insertion part  16 , and a holder part  17  provided integrally on one end of the insertion part  16 , and is made, for example, of plastic etc. 
         [0080]    By inserting both insertion parts  16  of the holding tool  15  into both insertion parts  14  of the cleaning member  1 , and engaging the protrusions  16   a  with two second melt-bonding parts  11 , the cleaning member  1  can be mounted to the holding tool  15 . By holding the holder part  17  of the holding tool  15 , and allowing the brush sheet  2  to come into contact with a target cleaning site to move it in the desired direction, dust, etc., at the target cleaning site are trapped by the brush sheet  2 , resulting in the cleaning of the target cleaning site. 
         [0081]    The cleaning member shown in  FIG. 1  through  FIG. 3  is an example of a cleaning member that can be produced by the method and system of producing a cleaning member according to the present invention. The method of producing a cleaning member and the system of producing a cleaning member according to the present invention can be used in producing cleaning members as described in, for example, Japanese Unexamined Patent Publication Nos. 2000-296083, 2003-265390, 2003-268663, 2004-223692, 2005-046645, 2005-095665, 2005-111284, 2005-137929, 2005-137930, 2005-137931, 2005-144198, 2005-169148, 2005-199077, 2005-230573, 2005-237975, 2006-015164, 2006-034990, 2006-141483, 2007-135774, 2007-209460 and 2007-209461, 2007-029136, 2007-111297, 2007-135666, 2007-136156, 2007-159612, 2007-236690, 2008-006260, 2008-119171, and 2007-029135, the entire disclosures of which are incorporated herein by reference. The method of producing a cleaning member and the system of producing a cleaning member according to the present invention can be used to produce a cleaning member as described in, for example, U.S. Pat. No. 6,554,937B, US2002/148061A, US2003/0000934A, US2004/0149095A, US2005/0005381A, US2005/039285A, US2005/097695A, US2005/097696A, US2005/132521A, US2005/177967A, US2005/188490A, US2005/193513A, US2005/193514A, US2005/198760A, US2006/016035A, US2006/016036A, US2006/101601A, US2009/165230A and US2009/172904A, as well as US2009/049633A, US2009/255078A and US2010/154156A, the entire disclosures of which are incorporated herein by reference. 
         [0082]    Next, an embodiment of a method and a device for producing a cleaning member  1  will be explained with reference to  FIG. 4 . 
         [0083]      FIG. 4  is a schematic view for explaining a method and the device for producing a cleaning member  1 , and in the present embodiment, the method of producing the cleaning member  1  is carried out using a device  100  shown in  FIG. 4  to produce the cleaning member  1 . 
         [0084]    In the present embodiment, the method of producing the cleaning member  1  comprises the following step  1  and step  2 . 
         [0085]    [Step  1 ] A step of opening fiber bundles, conveying the bundles, and detecting a connecting part of the bundles. 
         [0086]    [Step  2 ] A step of producing a multi-layer web using the fiber bundles, dividing (cutting) the multi-layer web into the cleaning members  1 , and ejecting any of the cleaning members  1  that comprise the connecting part of the fiber bundles. 
       &lt;Step  1 &gt; 
       [0087]    Hereinbelow, step  1  will be explained. 
         [0088]    In the present embodiment, step  1  comprises the following step  1   a  and step  1   b.    
         [0089]    [Step  1   a ] A step of opening first to fourth fiber bundles F 1 -F 4 . 
         [0090]    [Step  1   b ] A step of conveying the first to fourth fiber bundles F 1 -F 4  and detecting a connecting part b ( FIG. 5 ) of the fiber bundles F 1 -F 4 . 
         [0091]    According to the present embodiment, while step  1  comprises step  1   a , the presence or absence of step  1   a  can be selected as appropriate depending on the type etc. of the fiber bundle used. In another embodiment, an embodiment in which step  1   a  is omitted can be mentioned. For example, when fiber bundles are composed of a noncurled fiber, step  1   a  can be omitted. 
         [0092]    [Step  1   a]   
         [0093]    Hereinbelow, the step  1   a  will be explained with reference to a step of opening the first fiber bundle F 1  by way of example, and steps of opening the other fiber bundles F 2 -F 4  can be carried out in a similar manner. 
         [0094]    The first fiber bundle F 1  composed of a curled fiber is continuously extracted from housing containers  201  and  202  ( FIG. 5 ), and conveyed to first nip rolls  102   a  and  102   b  revolving at a constant peripheral velocity V 1 . The first fiber bundle F 1  that passed through the first nip rolls  102   a  and  102   b  passes through a plurality of tension rolls  104 , and is conveyed to second nip rolls  106   a  and  106   b  revolving at a peripheral velocity V 2 . 
         [0095]    The peripheral velocity V 2  of the second nip rolls  106   a  and  106   b  is faster than the peripheral velocity V 1  of the first nip rolls  102   a  and  102   b . Due to the difference in the peripheral velocities, tension is imparted to the first fiber bundle F 1  between the first nip rolls  102   a  and  102   b  and the second nip rolls  106   a  and  106   b , resulting in the opening of the first fiber bundle F 1 . 
         [0096]    Each tension roll  104  is formed, for example, of a solid steel, and the weight has been adjusted to require a significant degree of force for revolving. Thus, during the movement of the first fiber bundle F 1 , while rotating each tension roll  104 , from the first nip rolls  102   a  and  102   b  toward the second nip rolls  106   a  and  106   b , the moving speed of the first fiber bundle F 1  has been adjusted not to increase abruptly. 
         [0097]    In order to attain the gradual opening of the first fiber bundle F 1 , each tension roll  104  has been disposed so as to lengthen the distance between the first nip rolls  102   a  and  102   b  and the second nip rolls  106   a  and  106   b.    
         [0098]    The first fiber bundle F 1  that passed through the second nip rolls  106   a  and  106   b  passes through an air supplier  108  and is conveyed to third nip rolls  112   a  and  112   b . The peripheral velocity V 3  of the third nip rolls  112   a  and  112   b  is slower than the peripheral velocity V 2  of the second nip rolls  106   a  and  106   b . Due to the difference in the peripheral velocities, the first fiber bundle F 1  is relieved, between the second nip rolls  106   a  and  106   b  and the third nip rolls  112   a  and  112   b , from the tension applied between the first nip rolls  102   a  and  102   b  and the second nip rolls  106   a  and  106   b , resulting in the further opening of the first fiber bundle F 1  as well as the widening of the width of the first fiber bundle F 1 . 
         [0099]    On the first fiber bundle F 1  that is conveyed from the second nip rolls  106   a  and  106   b  to the third nip rolls  112   a  and  112   b , air is blown from the air supplier  108 , resulting in the further opening of the first fiber bundle F 1 . 
         [0100]    According to the present embodiment, while the first fiber bundle F 1  is opened using the application and release of tension and air blowing, the method of opening can be changed as appropriate. In another embodiment, there can be mentioned an embodiment in which either of the application and release of tension or air blowing is used, and in still another embodiment, there can be mentioned an embodiment in which another method of opening is used in addition to the application and release of tension and air blowing. Also in the present embodiment, while the first through third nip rolls are used in the application and release of tension, the number of nip rolls can be changed as appropriate. In another embodiment, there can be mentioned an embodiment in which additional nip rolls are used for the application and release of tension in addition to the first through third nip rolls. 
         [0101]    An oil applicator  110  is further provided between the second nip rolls  106   a  and  106   b  and the third nip rolls  112   a  and  112   b . The oil applicator  110  applies, to the fiber bundle F 1 , an oil solution contained in an oil solution tank  114 , the solution having an effect of promoting the adsorption of dust, etc. 
         [0102]    [Step  1   b]   
         [0103]    Hereinbelow, the step  1   b  will be explained with reference to a step of conveying the first fiber bundle F 1  and a step of detecting the connecting part b thereof by way of example, and a step of conveying the other fiber bundles F 2 -F 4  and a step of detecting the connecting part b thereof can be carried out in a similar manner. 
         [0104]    After passing through the third nip rolls  112   a  and  112   b , the first fiber bundle F 1  passes under a first phototube  181  and proceeds to a merging part  132 . Similarly to the first fiber bundle F 1 , the second, third, and fourth fiber bundles F 2 , F 3  and F 4 , after passing through the third nip rolls (not illustrated), respectively pass under second, third and fourth phototubes  182 ,  183 , and  184  and respectively proceeds to merging parts  136 ,  138  and  140 . In the step  1   b , the phototubes  181 - 184  can respectively detect the passage of the connecting part b ( FIG. 5 ) of the fiber bundles F 1 -F 4  under the phototubes  181 - 184 . A mechanism for detecting the connecting part b of the fiber bundles F 1 -F 4  will be described in detail later. 
       &lt;Step  2 &gt; 
       [0105]    Hereinbelow, step  2  will be explained. 
         [0106]    In the present embodiment, step  2  comprises the following step  2   a  through step  2   c.    
         [0107]    [Step  2   a ] A step of laminating the fiber bundles F 1 -F 4  that underwent through the step  1   b  and another member (a belt-shaped nonwoven fabric in the present embodiment) to form a multi-layer web. 
         [0108]    [Step  2   b ] A step of fixing the fiber bundles F 1 -F 4  and the another member contained in the multi-layer web. 
         [0109]    [Step  2   c ] A step of dividing the multi-layer web into individual cleaning members  1  and ejecting any of the cleaning members  1  that comprise the connecting part b ( FIG. 5 ) of the fiber bundles F 1 -F 4 . 
         [0110]    [Step  2   a]   
         [0111]    Hereinbelow, step  2   a  will be explained. 
         [0112]    In the present embodiment, the other members that are stacked with the fiber bundles that underwent the step  1   b  are belt-shaped nonwoven fabrics  121 ,  123  and  151 . In another embodiment, one or two of these belt-shaped nonwoven fabrics are stacked with the fiber bundles that underwent the step  1   b , and in still another embodiment, another belt-shaped nonwoven fabric, in addition to these belt-shaped nonwoven fabrics, is stacked with the fiber bundles that underwent the step  1   b . In any of the embodiments, the order of stacking is not limited, but preferably stacking may be carried out so that the belt-shaped nonwoven fabric is positioned at the outermost layer. 
         [0113]    The belt-shaped nonwoven fabrics  121  and  123  correspond to the base sheet  12  and the holding sheet  13 , respectively, of the cleaning member  1 . The belt-shaped nonwoven fabric  121  is continuously curled out from an nonwoven fabric roll  120 , and is conveyed intermittently by passing through a dancer roll  124  comprising a plurality of rolls provided in two vertical stages wherein a roll located at the lower stage fluctuates vertically. Similarly, the belt-shaped nonwoven fabric  123  is continuously curled out from an nonwoven fabric roll  122 , and is conveyed intermittently by passing through a dancer roll  126  comprising a plurality of rolls provided in two vertical stages wherein a roll located at the lower stage fluctuates vertically. As used herein “is conveyed intermittently” means that the belt-shaped nonwoven fabrics  121  and  123  are conveyed by repeating the steps of proceeding by a given distance (for example, roughly the lateral length of the cleaning member  1 ) and then stopping conveying for a certain period of time. Thus, by the intermittent conveyance of the belt-shaped nonwoven fabrics  121  and  123 , the time required to fusion-bond the constituent elements of the multi-layer web described below can be secured. 
         [0114]    The belt-shaped nonwoven fabrics  121  and  123  form a multi-layer web S 1  at a merging part  128 , and the multi-layer web S 1  passes through a gather cutter  130  in which saw-edged blades (not shown) are intermittently formed on the surface thereof in a circumferential direction. This results in the formation of cuts corresponding to cuts  20   a  (see  FIG. 1 ) in the base sheet  12  and the holding sheet  13 . And the multi-layer web S 1  proceeds to a merging part  132 . 
         [0115]    At the merging part  132 , the multi-layer web S 1  merges with the first fiber bundle F 1  that underwent the step  1 , and the first fiber bundle F 1  is stacked on the multi-layer web S 1  to form a multi-layer web S 2 . The first fiber bundle F 1  is configured to become loosened slightly in between the third nip rolls  112   a  and  112   b  and the merging part  132 , and thus fulfills the same function as a dancer roll provided between them would do. 
         [0116]    At merging parts  136 ,  138  and  140 , the multi-layer web S 2  merges sequentially with the second fiber bundle F 2  through the fourth fiber bundle F 4  that underwent the step  1 , and the second fiber bundle F 2  through the fourth fiber bundle F 4  are stacked sequentially on the multi-layer web S 2  to form a multi-layer web S 3 . 
         [0117]    A belt-shaped nonwoven fabric  151  corresponds to the sheet with slits  7  of the cleaning member  1 . The belt-shaped nonwoven fabric  151  is continuously curled out from the nonwoven fabric roll  150 , and is intermittently conveyed by passing through a dancer roll  152 , and then passes through a gather roll  154 . The gather roll  154  has saw-edged blades (not shown) continuously formed on the surface of the roll in a circumferential direction, which results in the formation of saw-edged cuts (not shown) on the belt-shaped nonwoven fabric  151  that passed through the gather roll  154 . 
         [0118]    The belt-shaped nonwoven fabric  151  merges with the multi-layer web S 3  at a merging part  156 , and the belt-shaped nonwoven fabric  151  is stacked on the multi-layer web S 3  to form a multi-layer web S 4 . 
         [0119]    [Step  2   b]   
         [0120]    Hereinbelow, step  2   b  will be explained. 
         [0121]    Before merging with the second fiber bundle F 2  through the fourth fiber bundle F 4 , the multi-layer web S 2  passes through a second melt bonded part forming device  134 . The second melt bonded part forming device  134  fusion-bonds belt-shaped nonwoven fabrics  121  and  123  contained in the multi-layer web S 2  to the first fiber bundle F 1  to form two second melt-bonding parts  11  (see  FIG. 3 ). This results in the melt-bonding of the multi-layer web S 2  in the direction of the thickness thereof. In the present embodiment, while a heat sealing device is used as the second melt bonded part forming device  134 , another heat sealing device (such as an ultrasonic sealing device) may be used. 
         [0122]    The multi-layer web S 4  passes through a first melt bonded part forming device  158 . The first melt bonded part forming device  158  fusion-bonds the entire hole multi-layer web S 4  to form a first melt-bonding part  8  (see  FIG. 3 ) on the multi-layer web S 4 . This results in the melt-bonding of the multi-layer web S 4  in the direction of the thickness thereof. In the present embodiment, while a heat sealing device is used as the first melt bonded part forming device  154 , the heat sealing device can be changed as appropriate. In another embodiment, an ultrasonic sealing device is used. 
         [0123]    [Step  2   c]   
         [0124]    Hereinbelow, step  2   c  will be explained. The multi-layer web S 4  that passed through the first melt bonded part forming device  158  is cut in the lateral direction of the multi-layer web S 4  by a cutting device  160  to form individual cleaning members  1 . The cleaning members  1  including the connecting part b ( FIG. 5 ) of the fiber bundles F 1 -F 4  that are not substantially opened, the part being detected by the four phototubes  181 - 184  as described above, is ejected by an ejecting device  190 . Although not illustrated in detail in the figure, the ejecting device  190  is disposed on a side of a conveyance path for the cleaning members  1  and is a device that ejects the cleaning members  1  at the ejection point from the conveyance path by a command from a control unit (not illustrated) by, for example, pushing the cleaning member  1  out. The control unit comprises a main body such as, for example, a computer and a programmable logic controller (PLC), and the main body has a processor and a memory. The distance from the detection point at which the detecting unit detects the connecting part b of the fiber bundles F 1 -F 4  to the ejection point at which the ejecting device  190  ejects the cleaning members  1  from the conveyance path for the cleaning member  1  is constant. Thus, the number N of the cleaning members  1  obtained by the multi-layer web between the detection point and the ejection point, can be calculated by “(the distance from the detection point to the ejection point)/(the length L of a side of one of the cleaning members  1  (FIG.  3 ))”. When the detecting unit detects that the connecting part b of the fiber bundles F 1 -F 4  passed through the detection point, a detection signal is input into the control unit, which then starts to count the number of the cleaning members  1  passing through the ejection point. When the counted number reaches the number N of the cleaning members  1 , i.e., when a cleaning member  1  that includes the connecting part b of the fiber bundles reaches the ejecting part, the ejecting device is started to eject the cleaning member  1  that includes a connecting part b of the fiber bundles F 1 -F 4 . Ejection of only the Nth cleaning member  1  counted from the start of the count can prevent the low-quality cleaning members  1  that include the connecting part b of the fiber bundles F 1 -F 4  from being contained into the finished products. Alternatively, in order to more securely eject the connecting part b of the fiber bundles, (N±2)th ((N−2)th, (N−1)th, Nth, (N+1)th, and (N+2)th) cleaning members  1  or (N±1)th ((N−1)th, Nth, and (N+1)th) cleaning members  1  can be ejected. This is because also in a portion near the connecting part b of the fiber bundles, the fiber bundles F 1 -F 4  may be insufficiently opened. 
         [0125]    The cleaning member  1  produced according to the present embodiment contains the sheet with slits  7 , whereas a cleaning member produced by another embodiment does not contain the sheet with slits  7 . In the cleaning member  1  produced by the present embodiment, the receiving part  14  is disposed on the face of the cleaning member  1 , whereas in a cleaning member produced by another embodiment, the receiving part  14  is disposed in between any of adjacent fibrous members  3  through  6  by changing the order of stacking the base sheet  12  and the holding sheet  13  and the fibrous members  3  through  6 . This makes it possible to use both faces of the cleaning member  1  in cleaning. At this time, in order to facilitate the insertion of the insertion part  16  into the receiving part  14 , the longitudinal dimension (vertical dimension in  FIG. 3 ) of the base sheet  12  and the holding sheet  13  may preferably be made longer than that of the fibrous members  3  through  6 , and these dimensions can be arbitrarily determined. Also, at this time, the sheet with slits  7  may or may not be used, and the sheet with slits  7  may be disposed on both faces of the cleaning member  1 . 
         [0126]      FIG. 5  is a drawing that schematically illustrates that a first fiber bundle F 1  formed by connecting a preceding first fiber bundle F 1   a  and a following first fiber bundle F 1   b  that are respectively housed in a housing container  201  and a housing container  202  is diverted by non-revolving bars  301  and  302  to feed the first fiber bundle F 1  to nip rolls  102   a  and  102   b  ( FIG. 4 ). Thus, the portion indicated by the reference symbol “a” in  FIG. 5  of the fiber bundle F 1  is continued to  FIG. 4 . It should be noted that the step illustrated in  FIG. 5  is a process prior to the step  1   a  described above with reference to  FIG. 4 . The terminal end ea of the preceding fiber bundle F 1   a  and the starting end eb of the following fiber bundle F 1   b  is fixed by melt-bonding such as heat sealing or by adhesion such as hot melt to connect the fiber bundles F 1   a  and F 1   b  at the outer surface of the terminal end ea and the starting end eb, thereby realizing continuous production of the cleaning members  1 . In this embodiment, the terminal end ea and the starting end eb as described above are manually melt-bonded by using a handheld heat sealing device to form fixing parts HS ( FIG. 6 ). In another embodiment, the terminal end ea and the starting end eb as described above are handled by using a robot arm, etc., and are fixed each other by using a heat sealing device, etc. 
         [0127]      FIG. 6  is a schematic view of the connecting part b of two first fiber bundles F 1 . The connecting part b of the fiber bundles F 1  is securely fixed by forming the fixing parts HS, and thus the fiber bundles F 1  in the part are not opened. Thus, it is understood that the width of the bundles are not substantially increased even after the opening step (the step  1   a  as described above). 
         [0128]    In this embodiment, as illustrated in  FIG. 6 , the fiber bundles have three fixing parts HS. However, the fiber bundles may have one or two fixing parts HS as long as the fiber bundles F 1  are fixed sufficiently so that the connecting part b of the fiber bundles F 1  is not separated by the tension applied to the fiber bundles F 1  in the subsequent steps, or the fiber bundles may have four or more fixing parts HS. 
         [0129]    Now, a mechanism for detecting the connecting part b of the fiber bundles F 1 -F 4  by a detecting unit, which is pairs of phototubes  181 - 184  in this embodiment, in the end of the step  1   b  as described above will be described in more detail. Hereinbelow, as an example of detection of the connecting part b of the fiber bundles F 1 -F 4 , the case of the first fiber bundle F 1  and the first phototube  181  will be described. It is appreciated that, in the case of the second fiber bundle F 2  and the second phototube  182 , the case of the third fiber bundle F 3  and the third phototube  183  and the case of the fourth fiber bundle F 4  and the fourth phototube  184 , the connecting part b of the second fiber bundle F 2 , the connecting part b of third fiber bundle F 3  and the connecting part b of the fourth fiber bundle F 4  can be respectively detected by the second phototube  182 , the third phototube  183  and the fourth phototube  184  in the same mechanism as in the case of the first fiber bundle F 1  and the first phototube  181 . This allows ejection of low-quality cleaning members  1  that include the connecting part b of the fiber bundles F 1 - 4 , the part being not substantially opened. 
         [0130]      FIG. 7  is a view that schematically illustrates that a part of the first fiber bundle F 1 , the part being not the connecting part b, passes under a pair of phototubes  181  in the step of conveying the first fiber bundle F 1 . In  FIG. 7 , light irradiated parts LI, which are a surface part of the fiber bundle F 1 , the part being to be irradiated with light rays from a light-emitting part of the phototubes  181 , are spaced in the lateral direction the fiber bundle F 1  at a certain distance. In the case of  FIG. 7 , the width of the fiber bundle F 1  is increased by opening the fiber bundle F 1  to match the dimensions of the cleaning members  1 , and thus the light rays from the light-emitting part is reflected by the fiber bundle F 1 . Light-receiving parts of the phototubes  181  can detect both of the reflected lights, thereby determining that the part of the fiber bundle F 1  passing under the phototubes  181  is not the connecting part b of the fiber bundle F 1 . 
         [0131]      FIG. 8  is a view that schematically illustrates that the connecting part b of the first fiber bundle F 1  passes under a pair of phototubes  181  in the step of conveying the first fiber bundle F 1 . In  FIG. 8 , the connecting part b of the first fiber bundle F 1  lies under the phototubes  181 . The connecting part b is not substantially opened as described above, and the width of the bundle is not increased. Thus, the fiber bundle F 1  is not irradiated with the light rays from the light-emitting part of the phototubes  181 , the rays irradiating a surface of the fiber bundle F 1  in the condition as illustrated in  FIG. 7 . Then, the light-receiving part of the phototubes  181  cannot detect that the light rays from the light-emitting part is reflected, thereby determining that the part of the fiber bundle F 1  passing under the phototubes  181  is the connecting part b of the fiber bundle F 1 . In  FIG. 8 , both of the light-receiving parts of the phototubes  181  does not detect the reflected light, while when either of the light-receiving parts does not detect the reflected light, it can also be determined that the connecting part b of the fiber bundle F 1  is passing under the phototube  181 . As described above, in order for the phototubes  181  to detect the connecting part b of the fiber bundle F 1 , the phototubes  181  should be disposed considering the detection accuracy so that the distance between the light irradiated parts LI is larger than the width of the connecting part b of the fiber bundle F 1  and is smaller than the wide of the parts of the fiber bundle F 1 , other than the connecting part b. 
         [0132]    In this embodiment, to detect the connecting part b of the fiber bundle F 1 , the phototubes determine whether the length in the lateral direction of the fiber bundle F 1  is smaller than a predetermined length, which is the distance between the light irradiated parts LI. In another embodiment; however, the thickness of the fiber bundle F 1  may be determined, or the difference between the hardness of the connecting part b and the hardness of a part other than the connecting part b of the fiber bundle F 1  may be determined by, for example, a contact sensor, since the fixing part HS is hard due to the melt-bonding or the adhesion. 
         [0133]    The present application claims the benefit of the following patent applications, the entire disclosures of which are incorporated herein by reference: 
         [0134]    (1) JP Patent Application No. 2012-289181 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0135]    (2) JP Patent Application No. 2012-289182 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0136]    (3) JP Patent Application No. 2012-289174 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0137]    (4) JP Patent Application No. 2012-289189 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0138]    (5) JP Patent Application No. 2012-289175 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0139]    (6) JP Patent Application No. 2012-289188 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0140]    (7) JP Patent Application No. 2012-289179 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0141]    (8) JP Patent Application No. 2012-289177 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0142]    (9) JP Patent Application No. 2012-289184 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0143]    (10) JP Patent Application No. 2012-289178 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0144]    (11) JP Patent Application No. 2012-289176 filed on Dec. 29, 2012, and US patent application claiming priority thereof, 
         [0145]    (12) JP Patent Application No. 2013-002855 filed on Jan. 10, 2013, and US patent application claiming priority thereof, and 
         [0146]    (13) JP Patent Application No. 2013-002857 filed on Jan. 10, 2013, and US patent application claiming priority thereof. 
       REFERENCE SIGNS LIST 
       [0147]      1 : cleaning member;  2 : brush sheet (shaggy brush sheet);  3 : first fibrous member;  4 : second fibrous member;  5 : third fibrous member;  6 : fourth fibrous member;  7 : sheet with slits;  8 : first melt-bonding part;  11 : second melt-bonding part;  12 : base sheet;  13 : holding sheet;  14 : receiving part;  15 : holding tool;  16 : insertion part;  16   a : protrusion;  17 : holder part;  18 : melt-bonding line;  20 : reed-shaped part;  20   a : slit;  100 : cleaning member-producing device;  102   a  and  102   b : first nip rolls;  104 : tension roll;  106   a  and  106   b : second nip rolls;  108 : air supplier;  110 : transcription roll;  112   a  and  112   b : third nip rolls;  113 : blade member;  114 : oil solution tank;  120 ,  122  and  150 : nonwoven fabric rolls;  121 ,  123  and  151 : belt-shaped nonwoven fabrics;  124 ,  126  and  152 : dancer rolls;  128 ,  132 ,  136 ,  138 ,  140  and  156 : merging parts;  130 : gather cutter;  134 : second melt bonded part forming device;  154 : gather roll;  158 : first melt bonded part forming device;  160 : cutting device;  181 : first phototube (detecting unit);  182 : second phototube (detecting unit);  183 : third phototube (detecting unit);  184 : fourth phototube (detecting unit);  190 : ejecting device;  201  and  202 : housing containers;  301  and  302 : non-revolving bars; F 1 : first fiber bundle; F 2 : second fiber bundle; F 3 : third fiber bundle; F 4 : fourth fiber bundle; b: connecting part; ea: terminal end; eb: starting end.