JP2000006116A - Fiber board and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate an inserting work in a thermally compressing step by adhering a thermosetting resin to a fiber mat containing a coconut fiber as a main component, placing the mat on a plate-like material having a specific thickness and a specific upper surface temperature, inserting the mat between hot platens and compression molding the mat in a specific range, thereby performing a high strength and a good moisture permeability. SOLUTION: A thermosetting resin is adhered to a fiber mat 1 containing a coconut fiber as a main component, and cut in a suitable length according to a using purpose. The mat 1 is placed on a plate-like material (plate) 6. Here, a thickness of the plate 6 is suitably selected according to a material to be used, and to 1 to 20 mm. Further, a surface temperature of an upper surface of the plate 6 before placing the mat 1 is lower than 100 deg.C. Then, the plate 6 placing the mat 1 is inserted between hot platens of a compression molding machine, and compression molded at a range of 100 to 200 deg.C. Thus, the fiber plate having a high strength and a good moisture permeability is manufactured, and an inserting work in a thermally compressing step can be facilitated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an outer wall base material, a floor material, a floor base material, a tatami mat, a roof base material, a ceiling material, a house interior material and an interior base material, a heat insulating material for a building, a body edge material, a sound insulation. Wood that can be used as materials, sound absorbing materials, cushioning materials, shock absorbing materials, concrete formwork materials, loading pallets, ground stabilizing materials, drainage dark beams, vehicle interior materials such as automobiles, interior base materials, furniture materials, etc. For fiberboard similar to shaped fiberboard and its manufacturing method,
The present invention relates to a fiberboard excellent in moisture permeability and strength, and a method for manufacturing a fiberboard that can be easily inserted at the time of press molding.

[0002]

2. Description of the Related Art In a wooden house, a fiber-based heat-insulating layer such as glass wool is generally provided in a wall, and a ventilation layer is formed between the outer wall and the heat-insulating layer in order to release indoor water vapor to the outside. This allows the water vapor in the room that has passed through the heat insulating layer to diffuse from under the eaves to the outside through the ventilation layer. In that case, usually, a windproof layer is provided between the heat insulating layer and the ventilation layer in order to partition the heat insulating layer and the ventilation layer and hold the heat insulating layer. This windproof layer, besides having the function of holding the heat insulating layer, it is necessary that the water vapor that has passed through the heat insulating layer can be smoothly transmitted to the ventilation layer,
Therefore, those having excellent strength and moisture permeability are required.

[0003] Conventionally, for example, a nonwoven fabric made of polyethylene has been used as the windproof layer. However, since the strength is insufficient, when the heat insulating layer is made of glass wool or the like, the expansion force of the heat insulating layer is pressed. As a result, there is a disadvantage that the nonwoven fabric swells and deforms to narrow the ventilation layer. This is particularly likely to occur when a large amount of glass wool or the like is packed in a cold region.
24 Insulation work (edited by the Architectural Institute of Japan)]. Therefore, a sizing board, which is a kind of soft fiberboard with relatively low density and breathability among wood fiberboards, is placed on the outside of the heat insulation layer, and the edges are columns, studs, beams, girders, etc. Fixing to the material compensates for the lack of strength of the windbreak layer.

[0004]

However, even though the above-mentioned sizing board can withstand the expansion force of the heat insulating layer, it does not have sufficient strength to function as a structural face material. Therefore, the strength of the structural part around the seasing board had to rely exclusively on the above-mentioned structural members other than the seasing board.

Japanese Patent Application Laid-Open No. 8-336816 discloses a windproof layer made of a fiber board having both strength and moisture permeability, in which a thermosetting resin is adhered to a fiber mat made of coconut fibers, and this is thermocompression molded. ing. However, since the fiber mat made of coconut fiber has no rigidity, for example, when the size of the fiber mat made of coconut fiber is large, such as 1 mx 3 m, the fiber mat made of coconut fiber is used in the heat compression molding process. It is difficult to mechanically grasp and insert the end of the mat.

[0006] Further, when inserting both sides by hand, it is difficult to insert between the hot plates of the compression molding machine because the central portion is bent. Also, a table is provided in front of the compression molding machine,
It is difficult to insert and push the fiber mat made of coconut fiber once, and to insert it by pulling it from the thermocompression molding machine side, it is difficult to maintain the shape of the fiber mat made of coconut fiber.

In addition, a method of placing a Teflon-impregnated glass cloth sheet having a thickness of several hundreds of μm under a fiber mat made of coconut fibers and also pulling the Teflon-impregnated glass cloth sheet from the thermocompression molding machine side, also serving as a mold release. However, the rigidity of the glass cloth sheet impregnated with Teflon is insufficient, so that it is difficult to maintain the shape of the fiber mat made of coconut fibers and to position the fiber mat in the thermocompression molding machine. Therefore, it is difficult to automate for mass production.

The present invention is intended to solve the above-mentioned problems, and an object of the present invention is to provide a fiber board which has high strength and good moisture permeability, and which can easily insert a fiber mat made of coconut fibers in a heat compression step. It is to provide a manufacturing method of.

[0009]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve these problems, and as a result, have found that a fiber mat formed from palm fibers to which a thermosetting resin has adhered has an upper surface temperature of 100%. After placing on a plate having a thickness of less than 1 ° C and having a thickness of 1 to 20 mm, the sheet is inserted between hot plates of a compression molding machine to reach 100 to 20
A method for compression molding in the range of 0 ° C. was found, and the present invention was completed.

[0010] The present invention provides a process for adhering a thermosetting resin to a fiber mat containing palm fiber as a main component, and a method for applying a thermosetting resin to a fiber mat having a thickness of 1 to 20 mm and an upper surface temperature of less than 100 ° C. The present invention relates to a method for producing a fiberboard, which comprises a step of placing the sheet on a plate-shaped body, inserting the sheet between hot plates of a compression molding machine, and compression-molding at 100 to 200 ° C.

[0011] The present invention also provides a step of attaching a thermosetting resin to a fiber mat made of palm fiber, a step of forming a laminate including at least one layer of the fiber mat to which the thermosetting resin is attached, and the laminate. Is placed on a plate having a thickness of 1 to 20 mm having an upper surface temperature of less than 100 ° C., and then inserted between hot plates of a compression molding machine to perform compression molding in the range of 100 ° C. to 200 ° C. And a method of manufacturing a fiberboard.

The laminate is a laminate composed of at least one layer of a fiber mat to which a thermosetting resin is attached, or a knitted or woven fabric to which a thermosetting resin is attached. The knitted or nonwoven fabric may be disposed on at least one surface of the at least one layer of fiber mat laminate. Alternatively, the laminate is a laminate in which a knitted or nonwoven fabric provided with at least one layer of the thermosetting resin is sandwiched between at least one layer of fiber mat to which the thermosetting resin is attached.

[0013] It is preferably inserted between the hot plates of the compression molding machine.
Alternatively, compression molding is performed within 3 minutes after placing. . The above palm fiber
Is preferably oil palm fiber, and
The body is preferably metal, more preferably aluminum
The present invention, which is a nickel alloy or stainless steel,
A fiberboard manufactured by the method described above, wherein 3 to 50 N /
mm ^TwoFlexural strength, or 0.1 to 10 μg / (m^Two・ S
-A fiberboard having a moisture permeability coefficient of Pa).

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The step of adhering a thermosetting resin to a fiber mat formed from coconut fibers is carried out, for example, by the following apparatus. The hopper is disposed above the upstream side of the belt conveyor, facing the upper surface of the belt, and accommodates coconut fiber, which is a raw material of the fiber mat. The hopper drops and supplies the palm fiber to the upper surface of the belt of the belt conveyor so that the palm fiber occupies a predetermined width in a direction perpendicular to the traveling direction of the belt conveyor. The palm fiber dropped and supplied to the upper surface of the belt is sent to the downstream side of the belt conveyor along with the movement of the belt of the belt conveyor.
If necessary, a plurality of hoppers are arranged in series along the traveling direction. The needle punching device is arranged above the downstream side of the belt conveyor from the position of the hopper, facing the upper surface of the belt of the belt conveyor, and intertwining coconut fibers sent out on the belt conveyor to form a fiber mat. . If desired, the fiber mat can be further pressed or hot pressed, thereby further densifying.

As used herein, the term "coconut fiber" refers to coconut palm, oil palm, sago palm, date palm, sugar beet, nipa palm, sugar palm, pea palm, palm,
Includes fibers such as fibrous bark, petiole base fibers, and mesocarp fibers collected from palm plants such as sugar beet and black clogs, and also includes fibers obtained by defibrating empty fruit clusters such as oil palm. . The term "coco fiber" also includes a mixture of two or more coco fibers.

In the present invention, preferably, palm palm fibers, more preferably, palm fibers obtained by defibrating empty palm bunch are used. Oil palm palm fibers have less dusting properties than coconut palm fibers and do not adversely affect the working environment for defibration. The empty fruit cluster of the oil palm is a fibrous aggregate remaining after the oil palm fruit, which is a raw material of the oil palm, is collected, and does not need to be immersed in water for defibration. Furthermore, the empty fruit bunches have no specific use at present and can be obtained at low cost. The resulting oil palm fibers are usually about 100-600 μm in diameter,
And about 5 to 30 cm in length and made of a single fiber having high flexibility and rigidity. In addition, when the fibers are entangled with each other, a product having excellent holding power can be provided when nails are driven.

Other than the above-mentioned empty fruit bunch of oil palm, for example, coconut is immersed in water for a long period of time to soften the coconut shell, and then mechanically defibrated into a fiber form for use. In addition to coconut fibers, fibers other than coconut plants can be blended and used. Among them, it is preferable to use fibers derived from plants other than palm plants. As a fiber derived from a plant other than the coconut plant, for example, hemp fiber, bamboo fiber, or other vegetable natural fiber is used, and by entanglement these at the intersection of the coconut fiber, the bond strength between coconut fibers can be increased. . Fibers derived from plants other than palm plants are usually 5 to 100 parts by weight of palm fiber.
It can be used in the range of 30 parts by weight. The fiber mat may have various thicknesses depending on the application, and is usually 5 mm to 20 m.
m.

In the present invention, the fiber mat containing coconut fibers as a main component refers to coconut fibers or fibers obtained by developing coconut fiber-based fibers into a plate shape. In order to improve the handling of the fiber mat, a small amount of a thermosetting resin is attached to the fiber developed in a plate shape, or preferably, needle punching is performed to increase the entanglement of the fiber. The fiber mat formed from the palm palm fibers depends on the fiber packing density, but for example, a gap having a size of about 100 μm to 5 mm, preferably about 200 μm to 3 mm can be formed between the fibers. Can adjust the moisture permeability of the fiber mat. In addition, since the thermosetting resin easily and evenly spreads over all fiber surfaces due to the presence of the gap, the variation in the strength distribution of the obtained product is reduced, and a uniform product is easily obtained.

A pair of spray guns facing the upper and lower surfaces of the fiber mat are provided further downstream of the needle punch device. Thermosetting resin is supplied under pressure to the spray gun. The pair of spray guns spray the thermosetting resin toward the upper surface and the lower surface of the fiber mat sent out on the belt conveyor, and attach the thermosetting resin to the fiber mat.

The method of adhering the thermosetting resin to the fiber mat and / or the fiber is not limited to the above-mentioned application by spraying using a spray gun or the like. What is necessary is just to be able to adhere by some method, such as immersing a mat. As used herein, the term "thermosetting resin" includes phenolic resins, amino resins, and diallyl phthalate resins (DAP resins).

As the thermosetting resin, preferably, a phenol resin or an amino resin can be used, which can provide quick curing time and high productivity. As phenolic resin,
Novolak resin (acid catalyst, excess phenol), resole resin (basic catalyst, excess formaldehyde), phenol-melamine copolymer resin, phenol-urea copolymer resin, phenol-melamine-urea copolymer resin, alkylphenol modified phenol resin, rubber A modified phenol resin such as a modified phenol resin may be used. As the amino resin, a urea resin (urea resin), a melamine resin, a urea-melamine copolymer resin, a benzoguanamine resin, an acetoguanamine resin, or the like can be used. The thermosetting resin is usually used in the form of an aqueous solution or an aqueous dispersion.

If necessary, a plasticizer, a filler, a reinforcing material, an anti-sagging agent, a coloring agent, an antioxidant, an adhesion promoter, a curing catalyst, a physical property modifier and the like can be blended. As an adhesion-imparting agent,
For example, konjac, flour, starch and the like can be added. The fiber mat to which the thermosetting resin has adhered is cut into an appropriate length according to the purpose of use.

Next, the cut fiber mat is placed on a plate (hereinafter, referred to as a plate) and then compression-molded. One or more fiber mats can be placed depending on the intended use of the obtained fiber board. Also, if necessary, apply a release agent to the top of the plate,
Alternatively, a mold release sheet such as a Teflon sheet, a Teflon-impregnated glass cloth sheet, or a silicone sheet may be inserted to improve the formability after compression molding.

The plate has a polygonal handle at one end. The handle portion has a structure for inserting or pulling out a plate on which a fiber mat to which the thermosetting resin is attached is placed between hot plates of a compression molding machine described later. The handle is installed at one end in the long direction or one end in the short direction of the plate. The handle may have any shape as long as the plate on which the fiber mat is placed can be inserted or pulled out. Alternatively, a plate without a handle may be used, grabbing a plate edge or extruding a plate to insert or pull between the hotplates.

The material of the plate may be a metal (for example, aluminum, aluminum alloy, copper, copper alloy, magnesium, magnesium alloy, iron, carbon steel, alloy steel,
Stainless steel, graphite steel, titanium, titanium alloys, zirconium, zirconium alloys, etc., wood-based materials (plywood, hardboard, particleboard, etc.) and inorganic fiber materials (glass fiber, mineral fiber, etc.) can be used. Preferably, metal is used, and more preferably, aluminum alloy and stainless steel, which are less likely to rust and are inexpensive, can be used.
Metal plates have good thermal conductivity and can provide high productivity in hot compression molding.

The thickness of the plate is appropriately selected depending on the rigidity and thermal conductivity of the material used, and is usually 1 to 20 m.
m, preferably 1-10 mm thick. When the thickness of the plate is less than 1 mm, sufficient rigidity cannot be obtained, so that it is difficult to handle. When the thickness exceeds 20 mm, heat conduction is deteriorated, the compression time is lengthened, and productivity is reduced. The plate may be cut out at a part thereof, for example, at four corners of the plate, to suppress the warpage of the plate caused by a temperature difference between the upper surface and the lower surface of the plate. Next, the placed fiber mat to which the thermosetting resin is adhered is put into a compression molding machine together with the plate, and is usually set at 100 ° C to 2 ° C.
The fiberboard is formed by compression molding in the range of 00 ° C.

FIG. 1 illustrates a multi-stage press-type compression molding machine used for compression. The multi-stage heat compression molding machine shown in FIG. 1 includes a loader device 3 having a pusher 2 on the upstream side where the fiber mat 1 is inserted, and an unloader device 4 on the downstream side where the compression-formed fiberboard is drawn out. I have. The unloader device 4 includes, for example, an openable / closable gripping tool 5 as shown in FIG. 2 at an upstream end of the multi-stage heat compression molding machine, and easily pulls out the plate 6 on which the fiberboard is placed. To FIG. 2A shows the gripper 5 in an open state, and FIG. 2B shows the gripper 5 in a closed state.

The plate 6 on which the fiber mat 1 is placed is
The pusher 2 is manually or mechanically pushed in a direction indicated by an arrow A in FIG. 1 by placing the handle portion on the loader device 3 with the side on which the handle is located toward the downstream side of the compression molding machine.
Insert between the hotplates shown in the center of. The fiber mat inserted between the hot plates is compression molded into a fiber plate. If necessary, a release agent is applied to the surface of the hot plate to improve the releasability of the obtained fiberboard after compression molding.

By gripping the plate or the grip portion of the plate by the gripper 5 of the unloader 4, the plate 6 is pulled out together with the fiberboard in the direction indicated by the arrow B in FIG. Depending on the construction of the molding machine, it is also possible to press the plate 6 or to remove the fiberboard first and then remove the plate 6. After forming the plate, the fiberboard is removed, another fiber mat is placed, and the plate is used repeatedly.

The surface temperature of the upper surface of the plate before placing the fiber mat is less than 100 ° C., preferably less than 80 ° C. The lower limit is 0 ° C. or higher. However, if the temperature is low, a lot of energy and time are required for heating, so the temperature is preferably 10 ° C. or higher, more preferably 20 ° C. or higher. Compression molding is started within 3 minutes after insertion between hot plates of a multi-stage heating compression molding machine. Before compression molding fiber mat
When the thermosetting resin attached to the fiber mat touches the temperature exceeding 00 ° C., the curing gradually progresses, the amount of the thermosetting resin contributing to the adhesion at the time of compression molding decreases, and the strength tends to decrease. is there. After inserting the plate between the hot plates,
If the temperature exceeds 10 minutes, the upper surface temperature of the plate is reduced to 10 before compression molding.
This is because the temperature becomes 0 ° C. or higher, and the thermosetting resin attached to the fiber mat gradually cures, and the amount of the thermosetting resin contributing to the adhesion at the time of compression molding is reduced, which tends to reduce the strength.

The physical properties, for example, the density of the obtained fiberboard are determined by the type and amount of the thermosetting resin to be attached to the fiber mat, the thickness and amount of the fiber used for the fiber mat,
In addition, it is possible to select and control the compression ratio and the like at the time of the compression type, whereby it is possible to provide an optimum windproof layer material according to the construction situation. The density of the fiberboard is appropriately selected according to the strength and moisture permeability required for the fiberboard, and is usually 0.2 g / cm ³ to 1.
5 g / cm ³ , preferably 0.3 g / cm ^{3 to} 1 g / cm
³ , more preferably 0.35 g / cm ^{3 to} 0.7 g / c
m is ^3. The density of the fiber sheet is less than 0.2 g / cm ^3,
When the bending strength is less than 3 N / mm ² , for example, JIS
If the fiberboard of A-5905 does not satisfy the quality as a seasing board, and if it exceeds 1.5 g / cm ³ , the air permeability is insufficient and the fiberboard is compressed and fractured due to an increase in compression force. Compression molding becomes difficult because of the high possibility of performing the compression molding. In addition, it is heavy and difficult to carry.

The thickness of the fiberboard is appropriately selected according to the strength and moisture permeability required for the fiberboard depending on the purpose of use, and is usually in the range of 3 mm to 25 mm, preferably in the range of 9 to 20 mm. Fiberboard with a thickness of less than 3 mm has insufficient strength,
It is difficult to obtain a fiberboard exceeding 25 mm by compression molding. The basis weight of the fiberboard is defined by the thickness and density of the fiberboard. For example, a basis weight of 2.7 kg / m ² is specified for a thickness of 9 mm and a density of 0.3 g / cm ³ , and a basis weight of 5.4 kg / m ² is specified for a thickness of 9 mm and a density of 0.6 g / cm ^3. Is done.

The size of the gap between the fibers of the fiberboard can be adjusted by selecting the density of the fiberboard, and a fiberboard having excellent strength and moisture permeability can be obtained. For example, about 100-
Using palm fiber with a diameter of 600 μm as the main raw material,
Amino resin is used in an amount of 5 to 10 with respect to 100 parts by weight of the raw material fiber.
0 parts by weight, and the compression ratio during compression molding was reduced to 1 /
If the ratio is 10 to 繊 維, a fiberboard having a density of about 0.2 to 1.5 g / cm ³ and a gap of about 1 to 100 μm can be obtained. Fiberboard with a gap of about 5 to 50 μm combines excellent flexural strength and moisture permeability, and is therefore breathable but impermeable to rain and excellent in strength.

Such a fiber board is usually 3 to 50 N /
mm ² , preferably 10 to 40 N / mm ² , more preferably 15 to 30 N / mm ² . The bending strength is measured, for example, according to the measuring method of JIS-A-5905. Also, this fiberboard is usually 0.1 to 1
0 μg / (m ² · s · Pa), preferably 0.2 to 8 μ
g / (m ² · s · Pa), more preferably 0.5 to 5 μm
g / (m ² · s · Pa). The moisture permeability coefficient is measured, for example, according to the measurement method of JIS-Z-0208.

In one aspect of the present invention, a step of attaching a thermosetting resin to a fiber mat formed from coconut fibers,
Forming a laminate comprising at least one fiber mat to which the thermosetting resin is attached, and placing the laminate on a plate having a thickness of 1 to 20 mm and then inserting the laminate between hot plates of a compression molding machine The present invention provides a method for producing a fiberboard, which comprises a step of heat-compression molding.

The laminate is formed by laminating a sheet material such as a knitted fabric or a nonwoven fabric to which the thermosetting resin is adhered on at least one fiber mat to which the thermosetting resin is adhered. The laminate may have a sandwich structure in which the at least one fiber mat is sandwiched between a plurality of knitted or woven fabrics. Alternatively, the laminate may have a structure in which a knitted or woven fabric is sandwiched between a plurality of fiber mats. The sheet-like material such as a knitted fabric or a nonwoven fabric to which the thermosetting resin has been adhered can be obtained by the same process as the process of attaching the thermosetting resin to the fiber mat formed from the coconut fibers.

Alternatively, a laminate comprising at least one fiber mat to which a thermosetting resin is adhered is obtained by laminating a sheet-like material such as a knitted fabric or a nonwoven fabric on or under palm fibers at the time of producing the fiber mat. Formed. In this case, the needle punch device forms the fiber mat by entanglement of the coconut fibers in a nonwoven fabric-like or three-dimensional knitted structure, thereby increasing the peel strength of the fiberboard obtained. The thermosetting resin is attached after the needle punching process. The laminate may be formed by combining two or more kinds of sheet-like materials such as a knitted or woven fabric.

The raw material of the sheet material such as a knitted fabric or a nonwoven fabric used in the present invention is a natural fiber such as a plant fiber, a synthetic fiber, a mixed fiber of a synthetic fiber and a natural fiber, or a mixture of two or more of these. Can be As the natural fiber, cotton, hemp, silk, bamboo, sugarcane fiber, luffa fiber, pineapple fiber, banana fiber, kuryang fiber, fiber obtained from rice straw, wood fiber, animal hair and the like can be used. Further, as synthetic fibers, polyester fibers, aliphatic or aromatic polyamide fibers, aramid fibers, acrylic fibers, polyethylene fibers, polypropylene fibers, vinylon, rayon,
Fibers such as cupra, acetate, etc. may be used. further,
Knitted or nonwoven fabrics made of inorganic fibers such as glass fibers, carbon fibers, and asbestos fibers can also be used.

The sheet-like material such as knitted fabric or nonwoven fabric used in the present invention is preferably 10~1500g / m ^2, more preferably, 10~600g / m ^2, more preferably the basis weight of 10~350g / m ² And imparts excellent moisture permeability and moldability to the obtained fiberboard. As a preferred example of the knitted fabric, a cloth formed by knitting hemp yarn in which hemp fibers are twisted vertically and horizontally is exemplified. As used herein, the term "hemp" encompasses hemp from renal fibers such as jute, flax, kenaf and ambassador, and hemp from tissue fibers such as manila, sisal, New Zealand and Mauricias. The term "hemp fiber" means a fiber obtained by defibrating these hemp. Hemp fibers can provide a fiberboard that has a small dimensional change during water absorption and moisture absorption and a small decrease in strength during water absorption and moisture absorption.

Since the jute cloth is formed by knitting a jute fiber or the like having a high tensile strength and tensile modulus, the jute cloth itself exhibits excellent tensile strength and tensile modulus. The weave of the jute cloth is preferably selected from plain weave, twill weave, satin weave, nanaco weave (including regular and irregular), and more preferably selected from plain weave and twill weave. The jute yarn is preferably selected, and the jute count is 7.5 to 40.
Is selected from

The basis weight of the jute cloth is usually 1
00 g / m ^{2 to} 1200 g / m ² , preferably 100 g / m ²
m ^{2 to} 1000 g / m ² , more preferably 100 g / m
It is in the range of ^{2 to} 600 g / m ² . The basis weight is 100 g / m ²
If it is less than 50%, the dimensional change in the length direction at the time of water absorption exceeds 0.5%, and does not satisfy, for example, the quality of a sealing board in a fiberboard according to JIS-A-5905. Even if it exceeds 1200 g / m ² , the obtained dimensional stability and reinforcing effect are not significantly increased.

The nonwoven fabric has a lower strength than the knitted fabric, but can retain more thermosetting resin than the knitted fabric, and thus can give strength to the fiberboard after hot compression molding. The fibers forming the nonwoven fabric are not particularly limited, but, in general, natural fibers, particularly vegetable natural fibers, have larger irregularities on the surface than artificial fibers and provide a good bonding force with the fiber mat and are preferably used. Can be done. If necessary, natural fibers may be mixed with synthetic fibers such as nylon, polypropylene, polyethylene and polyester.

As a non-woven fabric formed from natural fibers,
For example, a nonwoven fabric formed by forming a web from hemp fiber by a dry method, hardening it with an adhesive such as a latex of natural rubber, and finishing by drying, and a paper formed by defibrating a wood fiber and forming by a wet papermaking method may be used. The nonwoven fabric formed from the heat-meltable fibers can be hot-melted with the fiber mat at the time of heat compression molding, and provide good adhesiveness and moldability. As such a non-woven fabric, a non-woven fabric formed from polypropylene, polyethylene, or polyester can be used. The fiber length, manufacturing method, and the like of the nonwoven fabric are not particularly limited. A nonwoven fabric made of short fibers and a nonwoven fabric made of long fibers can be used. Further, nonwoven fabrics manufactured by a general method such as a wet method, a dry method, a spun pond method, a flash spinning method, a melt blow method, a spunlace method, and the like can be used. The above knitted and woven fabrics generally have excellent air permeability and moisture permeability.

The amount of the sheet-like material to be laminated on the fiber mat is selected in consideration of the required physical properties such as dimensional stability and strength in accordance with the use of the fiber board, and a combination of the basis weight and the number of sheets to be laminated is selected. Is selected. Usually, the amount of the sheet is 5 to 50 parts by weight, preferably 5 to 30 parts by weight, more preferably 10 to 10 parts by weight, based on 100 parts by weight of the coconut fiber.
Used in a proportion of 25 parts by weight. For example, when hemp cloth is used as the sheet-like material, if the ratio to 100 parts by weight of the coconut fiber is less than 5 parts by weight, the dimensional change in the length direction at the time of water absorption exceeds 0.5%.

A fiber plate in which a sheet material such as a knitted fabric or a nonwoven fabric is disposed on the upper and lower surfaces of a fiber mat has a sandwich structure in which the fiber mat is sandwiched between a knitted fabric or a nonwoven fabric having higher strength or rigidity than the fiber mat. And thereby enhance the flexural strength and flexural modulus of the fiberboard. Alternatively, a sheet-like material such as a knitted fabric or a non-woven fabric,
The structure sandwiched by multiple fiber mats includes the tensile strength and tensile modulus, shear strength and shear modulus of the fiberboard, in-plane compressive strength (strength when subjected to compressive force in the plane stress state) and The in-plane compression elastic modulus (elastic modulus when receiving a compressive force in a plane stress state) is enhanced.

The sheet-like material such as a knitted fabric or a non-woven fabric disposed on the surface of the fiber mat can modify the surface characteristics of the fiberboard, and can maintain the fiberboard that does not need to be finished or the holding property of the finishing material attached to the surface. An excellent fiberboard can be provided. Sheets made of materials with excellent moisture permeability, such as hemp fiber,
A fiber board having high moisture permeability can be provided without impairing the excellent moisture permeability of the fiber mat. If a windproof layer is formed using such a fiberboard, water vapor can be smoothly transmitted to the gas permeable layer due to high moisture permeability, and the heat insulating layer can be stably held with high strength, and the vicinity of the windproof layer can be maintained. Structural parts can be reinforced.

When the fiber mat and the sheet-like material are vegetable natural fibers, the natural surface of the vegetable natural fibers is generally larger than that of the artificial fibers and the like, so that the degree of entanglement between the fibers is smaller than that of the artificial fibers. In addition, the fibers are bonded by a thermosetting resin that acts as an adhesive due to the so-called anchor effect (a phenomenon in which the adhesive penetrates into voids on the surface of the material and solidifies and acts like a nail or wedge). Can be further enhanced.

If necessary, wax, silicon or the like can be applied to the surface of a sheet-like material such as a knitted or woven fabric to improve the water resistance. Or depending on the application, a flame retardant, a coloring agent,
Bactericides, preservatives, termites and the like can be applied. The use of the fiberboard of the present invention is not limited to the windproof layer,
Excellent in strength, moisture permeability, and productivity, for example, exterior wall materials, floor materials, floor materials, tatami materials, roof materials, ceiling materials, house interior materials, interior materials, architectural insulation materials, body edge materials , Sound insulation,
It can also be used as a sound absorbing material, a cushioning material, a shock absorbing material, a concrete form material, a loading pallet, a ground stabilizing material, a drainage dark beam, a vehicle interior material such as an automobile, a vehicle interior base material such as an automobile, a furniture material, and the like.

[0049]

EXAMPLES Next, examples of the present invention will be described together with comparative examples, but the following examples are illustrative and do not limit the present invention. <Measurement method> Fiberboard Density After the fiberboard is cut into a rectangular parallelepiped shape, the fiberboard weight and fiberboard dimensions (thickness, length, width) are measured and determined from the weight and dimensions. 2. Flexural strength of fiberboard Measured according to the measuring method of JIS-A-5905. 3. Moisture Permeability Coefficient It was measured according to the moisture permeability test method of the moisture-proof packaging material of JIS-Z-0208. Example 1 15 parts of urea resin was adhered to ^two 1 m × 2.8 m oil palm fiber mats having a basis weight of 1.6 kg / m ² with respect to 100 parts by weight of the oil palm fiber mat in terms of solid content. Separately, the basis weight of 0.28 kg / m ²
The urea resin was adhered to two mx2.8 m jute cloths at a solid content of 10 parts by weight based on 100 parts by weight of the jute cloth in terms of solid content. Next, 1.2mx3mx2
1.2m × 3m × 0.35mm on a plate made of stainless steel (SUS304 · 2B) having a top surface temperature of 25 ° C.
A release sheet of a Teflon-impregnated glass cloth having a thickness of 2 mm was placed on the mold release sheet. The jute cloth to which the above urea resin was adhered, the two above-mentioned oil palm fiber mats, and the jute cloth were stacked in this order, and then another release sheet of a Teflon-impregnated glass cloth was placed thereon. Next, the two sides of the stainless steel plate are held by two people, and once placed on a table having a roll that can move freely, the plate is pushed in this state, and the table is slid on the table to laminate the laminate together with the plate. Was inserted. One minute after the insertion, compression molding was started under the conditions of 170 ° C. and a load of 70 Ton, and compression molding was performed for 8 minutes to obtain a fiberboard having a thickness of 9 mm and a density of 0.48 g / cm ³ . The obtained fiberboard has a bending strength of 15.5 N / mm ² ,
The moisture permeability coefficient at 40 ° C.-90% is 2.3 μg / (m ² · s ·
Pa). (Example 2) 15 parts of urea resin was adhered to ^two 1 m x 2.8 m oil palm fiber mats having a basis weight of 1.6 kg / m2 per 100 parts by weight of the oil palm fiber mat in terms of solid content. Separately, the unit weight of 0.28 kg / m ²
The urea resin was adhered to two mx2.8 m jute cloths at a solid content of 10 parts by weight per 100 parts by weight of the jute cloth in terms of solid content. Next, 1.2mx3mx2
1.2 m × 3 m × 0.35 mm on a plate made of stainless steel (SUS304 / 2B) having a top surface temperature of 60 ° C.
A release sheet of a Teflon-impregnated glass cloth having a thickness of 2 mm was placed on the mold release sheet. The jute cloth to which the urea resin was adhered, the two above-mentioned oil palm fiber mats, and the jute cloth were stacked in this order, and then another release sheet of a Teflon-impregnated glass cloth was placed thereon.

Next, a stainless steel plate is held by two persons on both ends, and once placed on a table having a freely moving roll, the plate is pushed in that state, and the plate is slid on the table to heat the laminate together with the plate. It was inserted into a compression molding machine. After insertion,
After 1 minute, compression molding was started under the conditions of 170 ° C. and a load of 70 Ton, and compression molding was performed for 8 minutes to obtain a fiberboard having a thickness of 9 mm and a density of 0.48 g / cm ³ . The obtained fiberboard had a bending strength of 15.0 N / mm ² and a moisture permeability coefficient of 40 μC-90% of 2.3 μg / (m ² · s · Pa). (Comparative Example 1) 15 parts of a urea resin was attached to ^two 1 m x 2.8 m oil palm fiber mats having a basis weight of 1.6 kg / m2 per 100 parts by weight of the oil palm fiber mat in terms of solid content. Separately, the basis weight of 0.28 kg / m ²
The urea resin was adhered to two mx2.8 m jute cloths at a solid content of 10 parts by weight based on 100 parts by weight of the jute cloth in terms of solid content. Next, 1.2mx3mx2
1.2m × 3m × 0.3 on a plate made of stainless steel (SUS304 ・ 2B) having a top surface temperature of 130 ° C.
A release sheet of 5 mm Teflon-impregnated glass cloth was placed. The jute cloth to which the above urea resin was adhered, the two above-mentioned oil palm fiber mats, and the jute cloth were stacked in this order, and then another release sheet of a Teflon-impregnated glass cloth was placed thereon.

Next, the both ends of the stainless steel plate are held by two people, and once placed on a table having a freely moving roll, the plate is pushed, and the laminated body is thermally compressed together with the plate by sliding on the free roll table. It was inserted into the molding machine. One minute after the insertion, compression molding was started under the conditions of 170 ° C. and a load of 70 Ton, and compression molding was performed for 8 minutes to obtain a fiberboard having a thickness of 9 mm and a density of 0.48 g / cm ³ . The obtained fiberboard had a bending strength of 10.2 N / mm ² and a moisture permeability coefficient of 40 μC-90% of 2.3 μg / (m ² · s · Pa). (Comparative Example 2) 15 parts of urea resin was adhered to ^two 1 m x 2.8 m oil palm fiber mats having a basis weight of 1.6 kg / m2 per 100 parts by weight of the oil palm fiber mat in terms of solid content. Separately, the basis weight of 0.28 kg / m ²
The urea resin was adhered to two mx2.8 m jute cloths at a solid content of 10 parts by weight based on 100 parts by weight of the jute cloth in terms of solid content. Next, 1.2mx3mx2
1.2m × 3m × 0.35mm on a plate made of stainless steel (SUS304 · 2B) having a top surface temperature of 25 ° C.
A release sheet of a Teflon-impregnated glass cloth having a thickness of 2 mm was placed on the mold release sheet.

The jute cloth to which the above urea resin was adhered, the above-mentioned two oil palm fiber mats, and the jute cloth were stacked in this order, and another release sheet of a glass cloth impregnated with Teflon was placed thereon. . Next, the two ends of the stainless steel plate were held by two people, and once placed on a table having a freely moving roll, the plate was pushed in that state, and the plate was slid on the free roll table and inserted into the thermocompression molding machine. . Five minutes after the insertion, compression molding was started under the conditions of 170 ° C. and a load of 70 Ton, and compression molding was performed for eight minutes to obtain a fiberboard having a thickness of 9 mm and a density of 0.48 g / cm ³ . The obtained fiberboard has a bending strength of 9.8 N / mm ² , 4
The moisture permeability coefficient at 0 ° C.-90% is 2.3 μg / (m ² · s · P
a).

Table 1 shows the production conditions of Examples 1 and 2 and Comparative Examples 1 and 2, and the density, bending strength and moisture permeability of the obtained fiberboard.

[0054]

[Table 1]

As shown in Table 1, the fiber boards obtained in Examples 1 and 2 had good strength and good moisture permeability. In Comparative Example 1, since the plate upper surface temperature exceeded 100 ° C., the strength was inferior. In Comparative Example 2, the compression molding was started more than 3 minutes after being inserted between the hot plates, so that the strength was inferior.

[0056]

As described above, according to the fiberboard manufacturing method of the present invention, the fiberboard suitable for the windproof layer has high strength, good moisture permeability, easy insertion work in the heat compression step. Can be provided.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of an exemplary multi-stage press-type compression molding machine used in the practice of the present invention.

FIG. 2 is a partial cross-sectional view of a gripper provided at an end of an unloader device of the multi-stage press-type compression molding machine. (A) shows the gripper in an open state, and (b) shows the gripper in a closed state.

[Explanation of symbols]

 Reference Signs List 1 fiber mat 2 pusher 3 loader device 4 unloader device 5 gripper 6 plate

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2B230 AA07 AA30 BA01 CB25 DA02 EA20 EB02 EB03 EB05 EB13 EB21 EB28 EB29 EC24 2B260 AA02 AA20 BA01 BA07 BA19 CB01 CD02 CD03 CD04 CD05 CD06 CD07 CD10 CD16 DA01 DA02 DA03 DA04 DA05 EB02 EB06 EB11 EB19 EB21 EB42 EC18 4F100 AJ04A AK01A AK46 BA01 DG11A EH03A EJ172 EJ421 EJ422 GB07 GB33 GB90 JA13 JB13A JD04 JK04

Claims (12)

[Claims] 1. A step of adhering a thermosetting resin to a fiber mat containing palm fibers as a main component, and a step of attaching the thermosetting resin to the fiber mat having an upper surface temperature of less than 100 ° C. in a thickness of 1 to 20 mm. A method for producing a fiberboard, comprising a step of inserting a hot plate of a compression molding machine between the hot plates of a compression molding machine after being placed on a plate-like body, and compression-molding the fiberboard at a temperature of 100 to 200 ° C. 2. A step of attaching a thermosetting resin to a fiber mat made of coconut fibers, a step of forming a laminate including at least one layer of fiber mat to which the thermosetting resin is attached, Is less than 100 ° C.
A method for producing a fiberboard, comprising a step of placing the sheet on a 20 mm plate-like body, inserting the sheet between hot plates of a compression molding machine, and compression-molding at 100 to 200 ° C. 3. The laminate, wherein at least one layer of a fiber mat to which a thermosetting resin is attached, or at least one layer of a fiber mat to which a thermosetting resin is attached, and a knitted fabric to which a thermosetting resin is attached. The method according to claim 2, which is a laminate made of a nonwoven fabric. 4. The method of claim 3, wherein the knitted or nonwoven fabric is disposed on at least one surface of the at least one layer of fiber mat laminate. 5. A knitted or nonwoven fabric to which at least one layer of thermosetting resin is attached is sandwiched between at least one layer of fiber mat to which said thermosetting resin is attached.
The method described in. 6. The method according to claim 1, wherein the compression molding is started within 3 minutes after being inserted between the hot plates of the compression molding machine. 7. The method according to claim 1, wherein the coconut fiber is an oil palm fiber. 8. The apparatus according to claim 1, wherein said plate is made of metal.
The method according to any of the above. 9. The method according to claim 8, wherein said metal is an aluminum alloy. 10. The method according to claim 8, wherein said metal is stainless steel. 11. A fiberboard produced by the method according to claim 1, wherein the fiberboard is 3 to 50 N / m.
Fiberboard with a bending strength of m ² . 12. A fiberboard produced by the method according to claim 1, wherein the fiberboard is 0.1 to 10 μg.
/ A fiberboard having a moisture permeability coefficient of (m ² · s · Pa).