CN87100798A - 木质纤维垫 - Google Patents

木质纤维垫 Download PDF

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CN87100798A
CN87100798A CN87100798.3A CN87100798A CN87100798A CN 87100798 A CN87100798 A CN 87100798A CN 87100798 A CN87100798 A CN 87100798A CN 87100798 A CN87100798 A CN 87100798A
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fibre
fiber mat
pad
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composite fibre
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CN1010201B (zh
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高田实
大堀英孝
中隆爱
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Development Of Cardboard Club
JNC Corp
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Chisso Corp
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Abstract

本发明提供一种主要由木质纤维、长纤维、热塑性纤维和热固性树脂构成的改进的木质纤维垫，它在加热和加压下，可以模塑成一定形状的产品，而且非常适合于深拉成型。该垫的特征在于，热塑性纤维是由许多熔点不同的成分构成的复合纤维；构成该垫的纤维互相缠绕，同时也受复合纤维中低熔点成分的熔融粘合和结合；热固性树脂则处于未固化的状态。

Description

本发明涉及的是主要由木质纤维构成的成型垫。
迄今已知，采用木质纤维作为主要原材料的成型垫包括：由长纤维和热塑性或热固性树脂粘合剂，与木质纤维混合而制得的产品（见日本专利申请公开号，昭51-43478/1976号）;以及，由低熔点热塑性纤维和热固性树脂，与木质纤维和长纤维混合，继而在低于热固性树脂的固化温度下，对所得混合物进行热处理，从而，通过热塑性树脂纤维的熔融粘合，而使所得材料的结构得以稳定的产品（见日本专利申请公开号，昭59-120440/1984号）等。按照前一个方法制得的产品，因垫的结构只是靠纤维间的缠绕而得以保持，故其强度较低，以致在成型时的输送过程中，或在向金属模具装配的工序中，都有发生破损的缺点;或者，在成型产品中也有易于发生龟裂的缺点。按照后一种制法，虽然垫的强度可有某种程度的提高，但因纤维之间的粘合是依赖于液滴状的熔融热塑性纤维，因此也就不可能利用热塑性纤维本身的强度，结果便有下述缺点：粘合点的分布稀疏;所制成的垫在成型时，尤其是在深拉成型时，仍然易于发生龟裂。
本发明的诸发明人，曾就克服普通木质纤维垫的上述缺点，进行了广泛的研究。
本发明的要点在于，该木质纤维垫主要是由木质纤维、长纤维、热塑性纤维、以及热固性树脂所构成，并且在加热和加压的条件下，可以模塑成有一定形状的产品。该垫的特征在于，所说的热塑性纤维是由许多具有不同熔点的成分构成的复合纤维;构成该垫的纤维互相缠绕，同时受到所说的复合纤维中较低熔点成份的熔融粘合和结合;而且，所说的热固性树脂呈未固化的状态。
本发明中所用之木质纤维指的是，将木片通过蒸煮并制成浆而获得的木质纤维;纸浆;以及由废纸制成浆的再生纸浆等，而它们都是构成木质纤维垫的主要成份。长纤维指的是棉、麻等类的植物纤维;羊毛等动物纤维;尼龙、聚酯一类的合成纤维等等。一般可以在制垫所需的，如下所述之热处理和成型期间受热而不会变坏的那些长纤维当中作适当的选择。继之，将那些纤维切成10至50毫米的纤维长度，然后，将所切的纤维和上述的木质纤维混合起来使用。木质纤维的主纤维长度一般短至1到2毫米，通过这种纤维与长纤维的混合，可以改善垫的成型性，进而，若相对于100重量份的木质纤维，使用10重量份或更多的长纤维的话，则会更好。
本发明中用作热塑性纤维的复合纤维指的是，由许多具有不同熔点的成分所组成的纤维。而这些纤维以并列型、鞘-芯型、或呈海中岛型排列，这样可使纤维中的较低熔点成分，可以沿着纤维的长度方向，至少占据一部分纤维表面。而较低熔点成分的熔点比下述热固性树脂的固化温度为低。在复合纤维中较低熔点成分与其它成分的熔点差，以及较低熔点成分的熔点与热固性树脂之固化温度的温差皆为20℃或大于20℃的情况时，制垫所需的热处理条件可有较宽的范围，因此这种情况较好。象这种较好的复合纤维的例子是，那些把聚乙烯、乙烯-乙酸乙烯酯共聚物、低熔点聚酯等用作较低熔点的成分，而把聚丙烯、聚脂、聚酰胺、聚丙烯腈等用作其它成分，而且这两种成分排列成并列型，或者按另一种形式，即其中用较低熔点成分作为“鞘”式“海”的成分，而把其它成分用作“芯”或“岛”的成分。这些复合纤维当中，以用低密度聚乙烯、乙烯-乙酸乙烯酯共聚物、或者主要由它们构成的，熔点等于或低于120℃的组合物，作为其中的较低熔点成分，而用聚丙烯作为其它成分，这样构成的复合纤维，不仅熔融粘合温度低，而且制垫的成本也低，此外两种成分的相互混溶性也很好，因此不会发生成分间的剥离;所以既使只添加少量此种纤维，而提高垫强度的效果却是显著的。此外，这种复合纤维可以采用那些粗细1至100旦（denier），更好的是1.5至20旦，和长度10至100毫米，更好的是25至50毫米的复合纤维。若粗细和长度超过上面的上限时，就会难于混合均匀，而若它们低于上述的下限时，就不能达到提高垫强度的效果。复合纤维对于100重量份木质纤维的混合比例为3或大于3重量份，而以5或大于5重量份为佳。若小于3重量份时，则增强效果不足。若超过20重量份的话，并未能显示出特别的效果，所以这种比例是不经济的。
本发明所用的热固性树脂是通过热处理而固化的，即是当本发明之木质纤维垫被压制成型为成型产品之际，所进行的热处理时发生固化的。该树脂可以从诸如酚醛树脂、脲素树脂、醇酸树脂等已知的热固性树脂之中，适当地选择应用。若热固性树脂是粉末状时，它与木质纤维等构成该垫的其它材料的混合就容易。若该树脂呈溶液状态时，通过喷雾即可达到均匀的混合。热固性树脂的混合比，可以根据所产生之成型产品所需的硬度与强度，进行适当的选择，一般对应于100重量份木质纤维的比例是5至30重量份热固性树脂。
本发明之木质纤维垫，除了上述四种原材料之外，需要时，还可向它添加石腊等防水剂、颜料、填料、阻燃剂等。
将木质纤维和其它原材料混合，并予先成型为具有所需宽度、厚度、长度以及基本重量的垫。然后，在复合纤维之较低熔点成分的软化点或更高温度，较好的是在其熔点或高于熔点，同时也在复合纤维之其它成分的熔点以下，以及热固性树脂的固化温度以下，对该垫进行热处理。热处理时，如果需要，在加压下，压缩该垫也是可能的。原材料的混合并无特别的限制，而且可以使用梳理机、制羊毛机、无规成网机等任何一种机器。在木质纤维是通过蒸煮木片，并使之成浆而制成纤维的情况下，使该纤维仍以未干燥的状态与长纤维、复合纤维和粉末状热固性树脂混合，藉此可避免热固性树脂粉末的脱落损失，而且，在上述热处理期间还可能进一步使该木质纤维干燥，因此，上述的混合方法是经济可取的。
热处理时发生软化或熔融的复合纤维中之较低熔点成份，并不形成任何液滴状凝聚物，而是广泛地蔓延到复合纤维的其它成分上，而且纤维的形状仍保持原样;因此，复合纤维不仅本身互相发生熔融粘合，而且它也和木质纤维，以及长纤维，于很多接触点上发生熔融粘合。同时，在热处理之后，这些复合纤维介入这些接触点之间，使它们连结在一起。因此由此制得的垫具有高强度和优异的弹性，而且可以防止搬运时发生破碎。此外，由于复合纤维产生的粘合点，因成型时的加热而被软化或熔融，所以垫的结构变为松散，使它可能较自然地吸收金属模具所给予的张力，同时在深拉成型时，既不会厚度不均匀，也不会发生爆裂。
本发明之木质纤维垫，作为各种领域的部件或货品的原材料很有用。它是通过加压和加热下，压制成型而制得的，它需要具有像汽车的门板、包装用的垫、家具、乐器盒等一类复杂而具立体的形状，以及相当大的硬度。
本发明将通过实施例和比较例作更加详细的说明。
实施例1、2，以及比较例1、2、3和4
把针叶树的木片进行蒸煮，并制成浆。将水蒸汽从所得材料中分离出去，从而获得长3毫米，含水量45%（重量）的木质纤维。用纤维长度已切至40毫米的麻作为长纤维。热塑料纤维则采用聚丙烯/低密度聚乙烯并列型复合纤维（复合比：50/50，粗细：3旦，长度：38毫米），低密度聚乙烯纤维（粗细：3旦，长度：38毫米），和聚丙烯纤维（粗细：3旦，长度：38毫米）。热固性树脂则采用粉末状酚醛树脂。
将上述原材料，按照表1所示之混合比，进行充分的混合。随后把该混合材料装入制垫的装置，以形成50毫米厚的垫。然后在热风循环式干燥炉中，于120℃加热该垫3分钟，之后用轧辊压缩，使其厚度为20毫米，由此制成木质纤维垫。此外，仅在参考例4的情况中是于160℃加热。表1中所示的混合比是以干基计的重量份为单位而表示的混合比。
将上述木质纤维垫在20公斤/厘米2压力下，于220℃温度，加热压缩一分钟，以进行深拉成型，所用的金属模具为制造汽车门之内侧面板用的模具，其长度为1100毫米、宽800毫米、厚20毫米，并于其中部有500毫米、宽100毫米、深70毫米的扶手。评价结果也示于表1。评价方法叙述如下。
垫的破损：
将长1100毫米、宽800毫米、厚20毫米的垫，用手转移到金属模具上时，发生破损的垫用X标记;发生变形者以△标记;而既无破损又不变形者，则以○标记。
成型产品的爆裂：
观察成型产品时，将有龟裂或燥裂者标记为X;良好者标作○。
成型产品的皱纹：
观察成型产品时，有皱纹者标以X，良好者标以○。
成型产品的硬度：
挠曲强度为300公斤/厘米2或其以上者，标记为○;挠曲强度为100公斤/厘米2或其以下者，标记为X;挠曲强度于其中间者标记为△。
总的评价：
深拉成型用的木质纤维垫，经判断而确认为优异产品者，标记为○;判断为非优异产品者标记为X。
如表1所示，满足本发明所要求的木质纤维垫，对于深拉成型极为适合。
实施例3、4、5以及比较例5和6
按照上述实施例的同样方法制备木质纤维垫，所不同者为采用下述物质作为热塑性树脂，即：聚酯/低熔点聚酯的鞘-芯型复合纤维（复合比50∶50，粗细5旦，长度40毫米），聚酰胺/乙烯-乙酸乙烯酯共聚物的鞘-芯型复合纤维（复合比50/50，粗细5旦，长度40毫米）聚酯/低密度聚乙烯的鞘-芯型复合纤维（复合比50/50，粗细5旦，长度40毫米），低熔点聚酯纤维（粗细5旦，长度40毫米），和聚酰胺纤维（粗细5旦，长度40毫米）。由此制得的木质纤维垫的组成及其评价结果示于表2。
如表2所示，满足本发明所要求的木质纤维垫非常适合于深拉成型。
Figure 87100798_IMG1
Figure 87100798_IMG2

Claims (4)

1、一种木质纤维垫，主要由木质纤维、长纤维、热塑性纤维、以及热固性树脂构成，并且在加热和加压下可以模塑成具有一定形状的产品，该垫的特征在于，所说的热塑性纤维是由许多具有不同熔点的成分构成的复合维维；构成该垫的纤维互相缠绕，同时也受到该复合纤维中较低熔点成份的熔融粘合和结合；而所说的热固性树脂处于未固化的状态。
2、按照权利要求1所述的木质纤维垫，其中所说的复合纤维之较低熔点成分是，低密度聚乙烯、乙烯-乙酸乙烯酯共聚物，或者主要由它们构成的，熔点等于或低于120℃的组合物;而该复合纤维的其它成分则是聚丙烯。
3、按照权利要求1所述的木质纤维垫，其中所说的复合纤维具有粗细1.5至20旦，长度25至50毫米。
4、按照权利要求1所述的木质纤维垫，其中所说的复合纤维相对于100重量份所说的木质纤维的混合比，是在5至20重量份的范围内。
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CN102438796A (zh) * 2009-05-15 2012-05-02 西姆佩尔坎普机械设备制造有限责任公司和两合公司 用于将纤维和粘结剂连续混合的方法和装置

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