JP2001303500A - Molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a molded product having a basic componential part composed of a fiber-laminated body and excellent in a strength, durability, moisture impermeability or a design. SOLUTION: This molded product comprises the basic componential part 10 composed of the fiber-laminated body 11 obtained by making the three- dimensionally shaped fiber-laminated body 11 from a slurry prepared by dispersing a fiber into a liquid by using a papermaking mold 2 and then drying the body 11 by using a drying mold. A different componential part 12 having a different layer structure from the basic componential part 10 is unitedly formed in the basic componential part 10.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded article having a fiber laminate obtained by making and drying a slurry containing fibers as a basic component, and a method for producing the same.

[0002]

2. Description of the Related Art In consideration of environmental problems, pulp molded products mainly made of pulp fibers or the like have been reviewed in place of molded products such as plastics. Such a pulp molded article is preferably formed only of a fiber laminate such as pulp fiber from the viewpoint of disposal, but strength, durability, non-permeability is required at desired locations, or the design is poor. May be required.

[0003] Accordingly, an object of the present invention is to integrate a basic constituent part composed of a fiber laminate with a different constituent part having a different layer constitution or compounding composition from the basic constituent part, thereby improving strength, durability, and the like.
An object of the present invention is to provide a molded article that can be made to have excellent moisture impermeability or excellent design and a method for producing the same.

[0004]

According to the present invention, a slurry in which fibers are dispersed in a liquid is used to form a three-dimensional fiber laminate using a papermaking mold, and then the fiber laminate is dried using a drying mold. A molded product mainly composed of a basic component part, wherein at least one of different configuration parts having a layer configuration or a composition different from that of the basic component part is integrally formed. The object has been achieved by providing a product.

According to a third aspect of the present invention, there is provided a method of manufacturing a molded article according to the third aspect, wherein the insert member is provided in the papermaking mold or the drying mold, and the insert member is formed in a papermaking step or a drying step. It is intended to provide a method for manufacturing a molded article to be integrated with the basic constituent part in a wet state or a dry state formed in the above. Further, the present invention is the method for producing a molded article according to claim 4, wherein the papermaking surface of the papermaking mold is defined or a part of the papermaking surface is coated, and the defined papermaking surface is formed. The present invention provides a method for producing a molded product in which slurries having different composition are respectively supplied to each part or the coated part and the uncoated part of the papermaking surface. The present invention also provides a method for producing a molded product according to claim 5, wherein the method comprises the step of impregnating a dry molded product formed in a drying step with a resin to cover the molded product. . Further, the present invention is the method for producing a molded article according to claim 4, wherein the fiber laminate is pressed and dehydrated or dried in the papermaking mold or the drying mold,
It is an object of the present invention to provide a method for producing a molded product in which the pressing force at a predetermined location is reduced, the fiber density of the location after drying is reduced, and the location is impregnated with a resin.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described based on preferred embodiments with reference to the drawings.

FIG. 1 shows a first embodiment of a molded article according to the present invention. In the figure, reference numeral 1 indicates a molded product. As shown in FIG. 1, the molded article 1 is a bottle container having an opening at an upper portion, and has a basic component 10 composed of a fiber laminate 11 on a body 1 a and a bottom 1 b thereof.
Different component 12 having a different layer configuration from basic component 10
In the mouth and neck 1c. Then, this different configuration part 12
Are formed integrally with the basic component 10.

The basic constituent part 10 is a three-dimensional fiber laminate 1 made of a slurry in which fibers are dispersed in a liquid using a papermaking mold.
1 is made, and then the fiber laminate 11 is dried using a drying mold.

The slurry used to make the fiber laminate 11 is a dispersion of fibers in a liquid. The fibers used for the slurry may be those usually used for this type of molded article, for example, those mainly composed of pulp fibers. The slurry may be composed of only pulp fiber and water.In addition to pulp fiber and water, inorganic materials such as talc and kaolinite, inorganic fibers such as glass fiber and carbon fiber, and thermoplastic synthetic resins such as polyolefin Powder or fiber, non-wood or vegetable fiber, polysaccharide and the like. The amounts of these components are
It is preferably from 1 to 70% by weight, especially from 5 to 50% by weight, based on the total amount of the pulp fibers and the components. Also,
Colored pigments, molding aids, and the like can be appropriately added to the slurry.

[0010] The different component 12 is formed from an insert member 13 formed in advance, and
0 is integrated in the papermaking process.

A thread 130 for screwing a cap is formed on the outer peripheral surface of the insert member 13.
A fitting ring 131 is formed below the thread 130. In addition, the peripheral wall portion of the insert member 13 is formed such that a fiber laminate is formed on the inner surface thereof in a paper making process.
A flow hole 132 for discharging a liquid component in the pulp slurry is formed. The hole diameter of the circulation hole 132 is preferably 0.05 to 5.0 mm from the viewpoints of easy discharge of the liquid component, prevention of clogging of the papermaking net, and discharge of steam during drying, and 0.1 to 5.0 mm. More preferably, it is 2.5 mm. The flow hole 132 has an opening area ratio per unit area,
Preferably more preferably 0.001~0.5m ² / m ^2, formed so as to 0.01~0.1m ² / m ^2.
Further, from the viewpoint of increasing the adhesion to the pulp layer, it is preferable to provide a ridge on the inner surface of the peripheral wall of the insert member 13. The ridges are preferably formed continuously or intermittently at predetermined intervals so as to cover the entire circumference of the inner surface of the peripheral wall portion. In the case where the insert member 13 is formed of, for example, a member made of paper having air permeability and water permeability, the communication hole 132 is not necessarily formed in the insert member 13.

It is preferable that the insert member 13 has a higher strength than the basic constituent part 10 and can obtain high shape accuracy. As those having such properties, resin molded members, molded members of pulp fiber and thermoplastic resin, molded members of pulp fiber and water-soluble resin, molded members of vulcanized pulp, resin impregnated or resin coated Pulp fiber and the like, among them, among these, the strength of the insert member, the shape accuracy and the fitting property with the basic constituent parts, adhesiveness,
A molded member of a composite material composed of pulp fiber and resin is preferred from the viewpoint of adhesion and environmental issues. The different constituent part in the molded article of the present invention is integrally formed with the basic constituent part composed of the fiber laminate in the papermaking step or the drying step, and plays a role as a molded article. Therefore, a container in which another member is fitted after papermaking and drying, for example, a container in which a resin spout is fitted in a container made of paperboard is not included.

The molded article 1 of the present embodiment is excellent in strength because the insert member 13 having high strength and high shape accuracy is integrated as the molded article 1 in the mouth and neck 1c where the cap is mounted. In addition, even if the cap is repeatedly opened and closed, the cap can be used without deteriorating the airtightness, and has durability to withstand repeated use. Moreover, the design of the insert member 13 and the basic component 10 can be improved by designing the color scheme.

Next, a method for manufacturing a molded article of the present invention will be described as a preferred embodiment based on the method for manufacturing the molded article 1 of the first embodiment, with reference to the accompanying drawings.
2A to 2D schematically show a paper making / dewatering step in the method for manufacturing the molded article 1 according to the present embodiment, wherein FIG. 2A shows a paper making step and FIG. 2B shows a core inserting step. , (C)
Is a pressure / dehydration step, and (d) is a demolding step. In the drawings, the structure, shape, and the like of the papermaking type are simplified for simplicity.

First, as shown in FIG.
The upper opening 23 of the papermaking mold 2 in which a cavity C having a shape corresponding to the outer shape of the molded article 1 to be molded is formed inside by abutting a pair of split molds 21 and 22 provided with the same.
Next, the filling nozzle 3 provided with the insert member 13 is arranged. Then, the slurry is injected under pressure into the cavity C through the filling nozzle 3. For pressure injection of the slurry, for example, a pressure pump (not shown) is used. The pressure of the slurry under pressure is preferably 0.01 to 5 MPa, more preferably 0.01 to 3 MPa. On the inner surface of the papermaking mold 2, a papermaking net (not shown) of a predetermined mesh for papermaking the fibers in the slurry is provided.

When the slurry is injected until the amount of the slurry in the cavity C reaches a predetermined amount, suction dehydration of the slurry through the suction path 20 is started. Thereby, the water in the slurry is discharged out of the papermaking mold 2 and the fibers are deposited on the inner surface of the cavity C (the inner surface of the papermaking net) and the inner peripheral surface of the insert member 12. Then, the hollow molded article 1 in a wet state in which the fiber laminate 11 and the insert member 13 are integrally formed in the cavity C is formed.

After supplying a predetermined amount of slurry, the supply of the slurry is stopped. Then, as shown in FIG. 2B, the inside of the cavity C is sucked and kept at a reduced pressure, and the elastic, expandable and contractible and hollow core 4 is inserted into the cavity C. The core 4 is used to give the inner surface shape of the cavity by inflating the cavity C like a balloon and pressing the fiber laminate 11 against the inner surface (papermaking surface) of the cavity. The core 4 is formed of urethane, fluorine-based rubber, silicone-based rubber, elastomer, or the like having excellent tensile strength, rebound resilience, elasticity, and the like.

Next, as shown in FIG. 2C, a pressurized fluid is supplied into the core 4 to expand the core 4, and the molded article 1 is placed on the inner surface of the cavity by the expanded core 4. Press. Then, the fiber laminate 11 in a wet state is expanded by the expanded core 4 and the inner surface of the cavity C and the insert member 1.
3, while the dehydration proceeds, the inner surface shape of the cavity is transferred to the fiber laminate 11,
Further, the insert member 13 is integrally joined. As described above, since the fiber laminate 11 is pressed against the inner surface of the cavity C from the inside of the hollow molded article 1, even if the shape of the inner surface of the cavity C is complicated, the shape of the inner surface of the cavity C is accurately adjusted. It will be transferred to the outer surface of the laminate 11. In addition, unlike the conventional method for manufacturing a molded product, there is no need to use a bonding step, and thus the obtained molded product does not have a seam or a thick portion due to bonding. As a result, the strength of the obtained molded article is increased and the appearance impression is improved. As the pressurized fluid used to expand the core 4, for example, compressed air (heated air), oil (heated oil), and other various liquids are used. The pressure for supplying the pressurized fluid is 0.01 to 5 MPa,
In particular, it is preferable to make it 0.1 to 3 MPa.

When the shape of the inner surface of the cavity C is sufficiently transferred to the outer surface of the fiber laminate 11 and the fiber laminate 11 can be dehydrated to a predetermined moisture content, as shown in FIG.
The pressurized fluid in the core 4 is drained. Then, the core 4 automatically shrinks and returns to its original size. Next, the contracted core 4 is taken out from the cavity C, the filling nozzle 3 is separated from the papermaking mold 2, and then the papermaking mold 2 is opened to obtain a wet fiber laminate (molded product) 1 having a predetermined moisture content. Take out.

The removed molded article 1 is then subjected to a drying step. In the drying process, except that papermaking and dewatering are not performed,
The same operation as in the paper making process shown in FIGS. 2 (a) to 2 (d) is performed. That is, first, a dry mold in which a cavity having a shape corresponding to the outer shape of a molded article to be molded is formed by abutting a pair of split molds is heated to a predetermined temperature, and the wet mold is placed in the dry mold. The article 1 is loaded.

Next, a core similar to the core 4 used in the papermaking step is inserted into the molded article, and a pressurized fluid is supplied into the core to expand the core. The molded product is pressed against the inner surface of the cavity by the core. The material of the core and the supply pressure of the pressurized fluid can be the same as in the papermaking process. In this state, the molded article is dried by heating. When the molded article is sufficiently dried, the pressurized fluid in the core is drained, and the core is shrunk and taken out. Further, the drying mold is opened, and the molded article is taken out.

As described above, according to the method of manufacturing the molded article 1 of the present embodiment, the molded article 1 can be suitably manufactured.

FIG. 3 shows a second embodiment of a molded article according to the present invention. In the figure, the same reference numerals are given to the same parts as those in the first embodiment, and the description will be omitted. The points of the first embodiment that are not particularly described are appropriately applied to the contents in the first embodiment.

As shown in the figure, the molded article 1 of the present embodiment
Is a bottle container having an opening at the top, having a basic component 10 composed of a fiber laminate 11 in its mouth and neck 1c, and a different component 12 having a layer configuration different from that of the basic component 10 to the body. 1a and the bottom 1b. That is, in the molded article 1 of the present embodiment, the portion other than the mouth and neck 1c is formed from the two-layered fiber laminates 11 and 11 '.

The molded article 1 of the second embodiment has a high buckling strength and excellent waterproofness (non-moisture permeable) because the body 1a and the bottom 1b have a two-layer structure. Further, by adding a coloring pigment different from the slurry in the first paper making process to the slurry in the second paper making process,
And other parts can be provided with different colors. By devising these colors, a bottle container having excellent design can be obtained. By blending a synthetic resin component with the slurry in the second papermaking step, a bottle container having excellent moisture resistance can be obtained.

Next, a method for manufacturing a molded article according to the present invention will be described as a preferred embodiment based on the method for manufacturing a molded article according to the second embodiment with reference to the accompanying drawings. FIGS. 4A to 4F schematically show the paper making and dewatering steps in the method for producing a molded article according to the present embodiment.
(A) is a first paper making step, (b) is a slurry filling nozzle replacement step, (c) is a second paper making step, (d) is a core inserting step, (e) is a pressurizing / dewatering step, (f) ) Is a demolding step. In the figure, for the sake of simplicity, the structure, shape and the like of the papermaking type are simplified.

First, as shown in FIG.
Assemble. Then, the filling nozzle 3 provided with the cylindrical masking member 5 is arranged in the upper opening 23 to cover a part of the inner surface of the cavity in the papermaking mold 2. Then, the slurry is injected under pressure into the cavity C through the filling nozzle 3. The pressure injection of the slurry is performed in the same manner as in the method for manufacturing a molded article of the first embodiment. The material of the masking member 5 is not particularly limited as long as it does not hinder the arrangement of the filling nozzle 3 and the suction and dehydration in the papermaking process and can prevent the accumulation of fibers at desired locations on the inner surface of the cavity. However, for example, those formed of a material such as rubber having elasticity can be used.

When slurry is injected until the amount of slurry in the cavity C reaches a predetermined amount, suction dehydration of the slurry through the suction path 20 is started. As a result, the water in the slurry is discharged to the outside of the papermaking mold 2 and the fibers are deposited on the inner surface of the cavity C, so that the fiber laminate 11 'is formed on the inner surface of the cavity C. In this first papermaking process,
No fiber laminate is formed on the portion of the inner surface of the cavity C covered with the masking member 5.

After supplying a predetermined amount of slurry, the supply of the slurry is stopped. Then, as shown in FIG. 4 (b), the filling nozzle 3 is detached from the papermaking mold 2, the masking member 5 is removed, and the masking member 5 is placed again in the upper opening 23 of the papermaking mold 2.

Next, as shown in FIG. 4 (c), a slurry having a different composition from the above-mentioned slurry was added to the cavity C again.
And pressurized. Then, when the slurry is injected until the amount of slurry in the cavity C reaches a predetermined amount, suction dehydration of the slurry through the suction path 20 is started. Thereby, the water in the slurry is discharged out of the papermaking mold 2 and the fibers are deposited on the inner surface of the cavity C, so that a hollow molded article is formed on the inner surface of the cavity C. In the second papermaking step, a new fiber laminate 11 is formed on the inner surface of the fiber laminate 11 ′ formed in the first papermaking step and on the portion covered with the masking member 5.

After supplying a predetermined amount of slurry, the supply of the slurry is stopped. The inside of the cavity C is sucked and kept at a reduced pressure, and the core 4 is inserted into the cavity C as shown in FIG.

Next, as shown in FIG. 4 (e), a pressurized fluid is supplied into the core 4 to expand the core 4, and the molded article 1 is moved by the expanded core 4 to the inner surface of the cavity C. Is pressed. Then, while dehydrating to a predetermined moisture content, the inner surface shape of the cavity C is transferred to the outer surface of the molded article 1. The pressurized fluid used to expand the core 4 and the pressure range for supplying the pressurized fluid are the same as those of the molded product 1 of the first embodiment.
Can be performed in the same manner as in the manufacturing method of

When the shape of the inner surface of the cavity is sufficiently transferred to the outer surface of the molded product and the molded product can be dehydrated to a predetermined moisture content, as shown in FIG. The core 4 that has been extracted and shrunk is taken out of the cavity C, and the papermaking mold 2 is further opened to take out a wet, undried molded article 1 having a predetermined moisture content.

The removed molded article is then subjected to a drying step. The drying step can be performed in the same manner as the drying step in the method for producing the molded article 1.

According to the method of manufacturing the molded article 1 of the present embodiment, the molded article can be suitably produced.

FIG. 5 shows a third embodiment of the molded article according to the present invention. In the figure, the same reference numerals are given to portions common to the molded article 1 of the first embodiment, and description thereof will be omitted. The points in the first embodiment described above are appropriately applied to the points that are not particularly described for the molded product of the present embodiment.

As shown in the figure, the molded article 1 of the third embodiment is a bottle container having an opening at the top, and has a basic component 10 composed of a fiber laminate 11 in its body 1a. The bottom part 1b and the mouth / neck part 1c have a different constitution part 12 having a different layer constitution from the basic constitution part 10. That is, in the molded article 1 of the present embodiment, the different component 12 is formed of the resin-impregnated portion, and the resin and the fiber coexist in the different component 12.

Acrylic, styrene, urethane, melamine, urea-formalin or olefin resin is used as the resin to be impregnated in the resin impregnated portion. These resins can be impregnated with an aqueous or non-aqueous (solvent-based) dispersion system. However, from the viewpoint of strength, durability, impregnation, and operability, a resin that forms an emulsion system (aqueous system) is preferably used. Can be The resin used for the resin impregnated part is
It can be appropriately selected according to the arrangement part of the different component,
A different resin may be used for each arrangement portion.

Since the molded article 1 of the third embodiment has the differently formed portion 12 formed of the resin-impregnated portion on the bottom 1b and the mouth and neck 1c, the molded article 1 is different from the case where it is formed only from the fiber laminate. It is excellent in strength, durability and moisture permeability. In particular, it is also excellent in water resistance at the bottom of the molded body when placed in an environment around water such as a sink. In addition, by adding a coloring pigment to the resin, the resin-impregnated portion and the basic component portion can have different colors, and the design can be excellent.

Next, a method of manufacturing a molded article of the present invention will be described as a preferred embodiment based on the method of manufacturing a molded article 1 of the third embodiment. The method for manufacturing a molded article according to the present embodiment includes the steps of:
Except for performing the dehydration, the molded article 1 of the first embodiment described above
Is the same as the paper making step and the drying step in the production method. Therefore, in the following description, only the method of impregnating the resin into the dried molded article obtained through the papermaking step and the drying step will be described.

The resin impregnation method is as follows: (1) A resin is coated or poured into a specific portion of a wet molded body after papermaking and before dehydration, and then the core is expanded so that dehydration is performed and the resin is placed inside. Impregnating and then drying,
(2) A method of injecting or dipping a dispersion system used in the resin-impregnated portion having a viscosity of 1000 mPa · s or less to a predetermined amount into a molded body after drying or impregnating the molded body by drying can be used. .

According to the production method of the present embodiment, a molded article having excellent strength, durability, moisture permeability or design can be suitably produced as compared with the case where the fiber laminate is formed only.

Next, a fourth embodiment of the molded product of the present invention will be described. The molded product of the present embodiment is obtained by forming the different configuration portion by a resin coating portion instead of the resin impregnation in the third embodiment. In the resin-coated portion, a layer (portion) in which fibers and resin coexist is provided below the coating layer made of resin alone, similarly to the resin-impregnated portion. The thickness of the layer in which both coexist can be appropriately set according to the portion where the resin coating portion is formed. Further, by forming the fiber density of a predetermined resin-impregnated portion (predetermined portion) of the molded product in a dry state lower than that of the non-resin-impregnated portion, the resin impregnating property can be increased, and the resin is impregnated. Since the amount of resin can be increased, physical properties such as water resistance and strength can be further improved. As a method for forming a portion having a low fiber density, (1) when pressing and drying or drying the fiber laminate in a papermaking mold or a drying mold, the pressing force applied to the fiber laminate is reduced only by the resin-impregnated portion. Method,
(2) In the method for manufacturing a molded article according to the fifth embodiment described below, a method of adjusting the composition of a slurry used for forming a resin-impregnated portion so as to reduce the fiber density, for example, using pulp fibers having a low degree of beating. And the like.

The resin used in the resin-impregnated portion of the third embodiment can be used for the resin-coated portion of the molded article of the fourth embodiment. Further, the resin used for the resin coating portion can be appropriately selected in accordance with the disposition portion of the different component portion, and a different resin can be used for each disposition portion.

The molded article of the fourth embodiment is similar to the molded article of the third embodiment except that paper making and dewatering are performed without disposing an insert member in a paper making mold. This is the same as the paper making step and the drying step in the method for producing the molded article 1 of the above. Therefore, in the following description, only the method of coating the resin on the dried molded article obtained through the papermaking step and the drying step will be described.

The resin coating method is as follows: (1) Spraying a resin dispersion used in the resin-impregnated portion to a predetermined thickness on a specific portion of the dried molded article, or immersing the specific portion in the resin liquid. (2) A method of spraying or immersing a resin melted in a specific portion of the dried molded body to a predetermined thickness or dipping in a resin solution to coat and dry; (3) Molding after drying A method of bonding a resin film to a specific part of the body by heat welding, ultrasonic welding, or binder bonding, or the like can be used.

As in the third embodiment, the molded article of the present embodiment has a different constitution portion formed of a resin-coated portion, and therefore has a higher strength and durability than a case where it is formed only of a fiber laminate. Excellent in water resistance and moisture permeability. In addition, by adding a coloring pigment to the resin, the resin-coated portion and the basic component portion can have different colors, and the design can be excellent.

FIG. 6 shows a fifth embodiment of the molded article of the present invention. The molded article of the fifth embodiment is a bottle container having an opening at the top, and has a basic component 10 made of a fiber laminate 11 at its body 1a and bottom 1b, and is different from the basic component 10. Different composition part 12 of compounding composition
At the mouth and neck 1c and the shoulder 1d. That is, the molded article 1 of the present embodiment is formed of the fiber laminate 11 ′ whose mouth and neck 1 c and shoulder 1 d have a composition different from those of the body 1 a and the bottom 1 b.

The molded article of the present embodiment has a different composition for the mouth and neck 1c and the shoulder 1d and the other parts, so that a bottle container excellent in strength, durability, moisture permeability or design is provided. It can be.

Next, a method for manufacturing a molded article according to the present invention will be described with reference to the drawings based on the method for manufacturing a molded article according to the fifth embodiment as a preferred embodiment.

In manufacturing the molded article 1 of the fifth embodiment,
For example, a slurry filling nozzle 3 having an on-off valve 30 and a cavity defining means 6 as shown in FIG.

As shown in FIG. 7A, the defining means 6 comprises:
A ventilation pipe 60 disposed inside the slurry supply pipe 31;
A hollow annular rubber 6 that can expand and contract by supply and suction of compressed air supplied from the ventilation pipe 60 through the ventilation pipe 60.
1 is provided. A window 31 a is provided in a peripheral wall portion of the supply pipe 31, and the window 31 a is a main shaft 30 a of the on-off valve 30.
Can be opened and closed in conjunction with the opening and closing of the on-off valve 30 by a shutter 30b provided in the shutter.

FIGS. 8A to 8F schematically show the paper making and dewatering steps in the method for producing a molded article according to the present embodiment using the above-mentioned slurry filling nozzle 3.
(A) is a slurry filling positioning step, (b) is a first paper making step, (c) is a second paper making step, (d) is a core inserting step, (e) is a pressurizing / dewatering step, and (f). Is a demolding step. In the figure, the structure, shape, and the like of the papermaking mold 2 and the slurry filling nozzle 3 are simplified for simplicity.

First, as shown in FIG.
Assemble. Then, the slurry filling nozzle 3 is inserted from the upper opening 23 and positioned.

Next, as shown in FIGS. 7 (b) and 8 (b), compressed air is supplied through a ventilation pipe 60 to expand the annular rubber 61, and the inside of the cavity C is filled with the cylinder of the molded article 1. The upper and lower chambers are watertightly defined by a portion corresponding to the portion 1a and the shoulder 1d. Then, while the opening / closing valve 30 is opened and the window 31a is closed by the shutter 30b, the slurry is injected under pressure into the lower chamber of the defined cavity C. The pressure injection of the slurry is performed in the same manner as in the method for manufacturing a molded article of the first embodiment. When the slurry is injected until the amount of slurry in the cavity C reaches a predetermined amount, suction dehydration of the slurry through the suction path 20 starts. As a result, the water in the slurry is discharged to the outside of the papermaking mold 2 and the fibers are deposited on the C inner surface of the cavity.
a and a basic component 10 having a bottom 1b.
In the first paper making process, no fiber laminate is formed in the upper chamber of the cavity C defined by the annular rubber 61.

After injecting a predetermined amount of slurry to form a desired fiber laminate, injection of the slurry and suction dehydration are stopped. Then, the air in the annular rubber 61 is sucked through the ventilation pipe 60 to contract the annular rubber 61, and the second rubber to be described later is used.
The supply pipe 31 is moved downward and positioned so that a different component formed in the paper making process can be continuously made with the basic component already formed.

Next, as shown in FIGS. 7 (c) and 8 (c), the annular rubber 61 is expanded again through the ventilation pipe 60 to define the cavity C in a watertight manner, and the on-off valve 30 is closed. With the window 31a opened, in the first paper making step, a slurry having a compounding composition having a low fiber density is injected under pressure into the cavity C. Then, when a predetermined amount of slurry has been injected, suction dehydration through the suction path 20 is started again, and the differently configured portion 12 made of a fiber laminate having a low fiber density of the mouth and neck portion 1c and the shoulder portion 1d is formed. It is formed integrally with the part 10. After the predetermined amount of slurry is injected, the injection of the slurry is stopped, and after the desired fiber laminate is formed, the suction dehydration is stopped. Then, the annular rubber 61 is contracted to separate the filling nozzle 3 from the papermaking mold 2.

Next, as shown in FIG. 8D, a nozzle having a core 4 is arranged in the upper opening 23 of the papermaking mold 2 in place of the filling nozzle 3, and the inside of the cavity C is sucked. Keep under reduced pressure.

Next, as shown in FIG. 8 (e), a pressurized fluid is supplied into the core 4 to expand the core 4, and the molded article 1 is moved by the expanded core 4 to the inner surface of the cavity C. Is pressed. Then, while dehydrating to a predetermined moisture content, the inner surface shape of the cavity C is transferred to the outer surface of the molded article 1. The pressurized fluid used to expand the core 4 and the pressure range for supplying the pressurized fluid are the same as those of the molded product 1 of the first embodiment.
Can be performed in the same manner as in the manufacturing method of

When the shape of the inner surface of the cavity is sufficiently transferred to the outer surface of the molded product and the molded product can be dehydrated to a predetermined moisture content, as shown in FIG. The core 4 that has been extracted and shrunk is taken out of the cavity C, and the papermaking mold 2 is further opened to take out a wet, undried molded article 1 having a predetermined moisture content.

The molded article taken out is then subjected to a drying step. The drying step can be performed in the same manner as the drying step in the method for manufacturing the molded article 1 of the first embodiment.

According to the method for manufacturing a molded product of the present embodiment,
The molded article of the fourth embodiment, which is excellent in strength, durability, moisture permeability, or design, can be suitably manufactured.

The present invention is not limited to the above embodiment.
For example, in the first embodiment, after the fiber laminate 11 and the insert member 13 are integrated in the papermaking process, a molded article is formed through a dehydration process using the core 4 and a drying process using a drying mold. After forming only the fiber laminate by dehydrating the fiber laminate in a core dehydrating step, an insert member is fitted into the opening thereof, and these may be integrated through a drying step by a drying mold. it can.

Further, as in the above embodiment, the present invention relates to a method for forming a paper-made article comprising the steps of assembling two split dies to form a paper-making mold, injecting slurry into the cavity of the paper-making mold to perform papermaking. Although it is particularly suitable for the production method, the present invention can be applied to a production method other than this production method, for example, in which a papermaking mold is immersed in a pool filled with slurry and the slurry is supplied into a cavity of the papermaking mold. Also, a split mold papermaking mold having a suction path is arranged with its papermaking surface facing upward, and an outer frame surrounding at least the papermaking surface is arranged in the papermaking mold in a liquid-tight manner, and the papermaking surface and After forming a pool for filling the slurry with the outer frame, the present invention is also applied to a manufacturing method of forming a molded article on a papermaking surface by filling a predetermined amount of slurry into the pool and sucking the slurry through the suction passage. be able to.

Further, according to the present invention, as in the first embodiment, the insert member 13 is formed by disposing the insert member 13 at a portion corresponding to the mouth and neck portion 1b of a molded product (container). And those formed by disposing an insert member at a portion corresponding to the bottom.

The present invention also includes a molded article having an injection portion such as a handle or a funnel. The member forming the handle or the injection portion is disposed as an insert member in a papermaking mold or a drying mold to form a papermaking process. Alternatively, it includes one integrated with the basic constituent part in the drying step.

In the first and second embodiments, the insert member 13 or the masking member 5 is provided on the filling nozzle 3, but they may be provided on the base of the pressurized dewatering core 4.

Further, in the above-described second embodiment, the different component is constituted by a two-layered fiber laminate, but it is needless to say that it can be constituted by a three or more-layered fiber laminate.

The present invention is suitable for hollow bottle containers as in the above embodiments, but is not limited thereto. For example, tableware such as plates, trays, articles having handles, decorative articles It is also suitable for ornaments such as handicrafts and folk crafts, and industrial members such as soundproofing materials and buffers.

[0070]

The molded article of the present invention is excellent in strength, durability, moisture permeability or design. Further, the method for producing a molded article of the present invention can suitably produce the molded article of the present invention.

[Brief description of the drawings]

FIG. 1 is a half-decision view showing a first embodiment of a molded article of the present invention.

FIG. 2 is a cross-sectional view of a paper making method according to the embodiment.
It shows the outline of the dehydration step, (a) is a pulp slurry injection / dehydration step, (b) is a core insertion step,
(C) is a pressurization / dehydration step, and (d) is a demolding step.

FIG. 3 is a half sectional view showing a second embodiment of the molded product of the present invention.

FIG. 4 shows an outline of a papermaking / dewatering step in the method for producing a molded article according to the embodiment, wherein (a) is a first example.
A paper making process, (b) a process of replacing a slurry filling nozzle,
(C) is the second papermaking step, (d) is the core insertion step, (e)
Is a pressure / dehydration step, and (f) is a demolding step.

FIG. 5 is a judgment view showing a third embodiment of the molded article of the present invention.

FIG. 6 is a judgment view showing a fifth embodiment of the molded article of the present invention.

FIG. 7 is a schematic cross-sectional view of a main part showing an operation of a filling nozzle used in the method of manufacturing a molded article according to the embodiment, where (a) is a view showing a state before slurry injection, and (b) is defined. The figure which shows the injection state of the slurry into the lower chamber of a cavity, (c)
FIG. 4 is a view showing a state of slurry being injected into an upper chamber of a defined cavity.

FIG. 8 schematically shows a paper making and dewatering step in the method for producing a molded article according to the embodiment, wherein (a) is a step of positioning a filling nozzle, (b) is a first paper making step, and (c).
Is a second papermaking step, (d) is a core insertion step, (e) is a pressure / dehydration step, and (f) is a demolding step.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Molded product 1a Trunk 1b Bottom 1c Mouth and neck 1d Shoulder 2 Papermaking mold 10 Basic component 11, 11 'Fiber laminate 12 Different component 13 Insert member

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Tokito Sono 2606, Akabane, Kaigamachi, Haga-gun, Tochigi Prefecture F-term (reference) 3E033 AA02 BA10 BA13 BB07 BB08 CA03 CA09 DA03 DB01 DD01 EA04 FA04 4L055 BF07 BF08 BF09 FA11 GA05

Claims (11)

[Claims] 1. A three-dimensional fiber laminate is formed from a slurry in which fibers are dispersed in a liquid using a papermaking mold, and then the fiber laminate is dried using a drying mold. A molded article, wherein at least one of different configuration parts having a different layer configuration or composition from the basic configuration part is integrally formed on the basic configuration part. 2. The molded article according to claim 1, wherein the fibers are mainly pulp fibers. 3. The molded product according to claim 1, wherein the different component is a preformed insert member, and the insert member and the basic component are integrated in a paper making process or a drying process. . 4. The molded article according to claim 1, wherein the different constituent part has a structure made of paper made from slurries having different composition. 5. The resin composition according to claim 1, wherein the different component is formed by a resin-coated portion or a resin-impregnated portion, and the resin-coated portion or the resin-impregnated portion has a portion where the resin and the fiber coexist. 2. The molded article according to 2. 6. The molded article according to claim 1, wherein the molded article is a container having an opening at an upper portion, and the modified component is provided at a mouth, neck, trunk, or bottom. 7. The method for producing a molded product according to claim 3, wherein the insert member is disposed in the papermaking mold or the drying mold, and the insert member is formed in a papermaking process or a drying process. A method for producing a molded article to be integrated with the basic component in a wet or dry state. 8. The method for producing a molded article according to claim 4, wherein the papermaking surface of the papermaking mold is defined or a part of the papermaking surface is coated. A method for producing a molded article, wherein a slurry having a different composition is supplied to each portion or a coated portion and an uncoated portion of the papermaking surface. 9. The method for producing a molded article according to claim 5, wherein the dried molded article formed in the drying step is impregnated with a resin and coated. 10. The method for producing a molded article according to claim 9, wherein slurries having different fiber densities are supplied as the slurries having different compounding compositions, and a resin having a low fiber density in a dry state is impregnated with a resin. 11. The method for producing a molded article according to claim 4, wherein when the fiber laminate is pressed and dehydrated or dried in the papermaking mold or the drying mold, a pressing force at a predetermined location is reduced. In addition, a method for producing a molded product in which the fiber density of the predetermined portion after drying is lowered and the portion is impregnated with a resin.