JP2002256698A - Form material and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a form material which is good in surface water resistance and releasability from a concrete skeleton, and excellent in uniform preheating performance of a form basic material, and to provide a method for producing the form material. SOLUTION: According to the method for producing the form material, the form basic material 1 is made of a mixed material which is prepared such that a mixing ratio of vegetable fibers to thermoplastic fibers is set within the range of 70/30 to 40/60, and both front and rear surfaces of the form basic material 1 are covered with air-permeable cloth-like materials 2 made of thermoplastic fibers. Then, the form basic material 1 covered with the cloth-like materials 2 are heated and pressurized, to thereby produce integrally the form material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mold material comprising plant fibers and thermoplastic fibers as main raw materials, and a method for producing the same. And a method for manufacturing the same, in which the form base material made of a mixed material of thermoplastic resin and thermoplastic fiber is uniformly heated in a short period of time while preventing the form collapse of the form base material so as to enhance energy efficiency at the time of molding. About the method.

[0002]

2. Description of the Related Art In recent years, in a situation where there is a shortage of waste disposal sites, pulp-based boards have been manufactured from a large amount of waste wood and waste paper discharged from business establishments and homes from the viewpoint of environmental protection. Has become. In addition, disposal of synthetic fiber waste such as curtains, carpets, clothes, etc. has also become a problem.

Conventionally, as a method of manufacturing a pulp-based board by using recycled resources, Japanese Patent Application Laid-Open No. H10-156810 discloses that a pulp-based fiber is mixed with an isocyanate-based adhesive and a plastic and heated to a predetermined shape. Pressing has been proposed. However, in the above publication, a plastic and an adhesive are added to pulp-based fibers such as defibrated waste paper from the viewpoint of easiness in making and strength of the board, and a laminated structure in which no resin is contained in the surface layer is adopted. Since the defibrated material is exposed on the surface, the surface is easily roughened and peeled. Therefore, such a fiber reinforced resin plate is not suitable for a concrete form member. Heating during heat molding relies on transmission from a hot press machine, resulting in poor energy efficiency. Further, there is a disadvantage that the adhesive cannot be reused because it is used.

[0004] On the other hand, Japanese Patent Application Laid-Open No. 2000-27431 proposes a method for producing a concrete form molding material using waste paper and waste plastic as main raw materials. However, in this case, unless the waste plastic, which is a strength component, is finely defibrated by impact destruction, fibrillated and integrated with the defibrated waste paper, it cannot be used as a board, and the process is complicated and the cost increases. In addition, this hot pressing method also has low energy efficiency because it relies on transmission from a hot press for heating during hot forming. Furthermore, the above-mentioned molding material has a structure in which the fibers are uniformly dispersed, and there are many places where the plant-based fibers are exposed on the surface. In addition, even in the case of a plywood form, the surface is currently coated to improve the releasability.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide a mold material having good surface water resistance and good releasability from a concrete structure, and excellent uniform preheating of the mold base material. It is to provide a manufacturing method.

[0006]

Means for Solving the Problems In order to achieve the above object, a formwork material of the present invention is made of a plant fiber and a thermoplastic fiber as main raw materials, and is integrally formed by covering both front and back layers with a thermoplastic resin. It is characterized by having. That is, both the front and back layers are resin layers, and the inside is a mold material in which the plant fiber and the thermoplastic fiber are completely integrated, and the front and back layers form a continuous layer without exposing the plant fiber. Such a mold material is excellent in surface water resistance and releasability from a concrete skeleton.

Further, in the method for producing a formwork material of the present invention, the mixing ratio of a short fiber material obtained by cutting and splitting a thermoplastic fiber into a plant fiber material obtained by dry-fibrillating a plant fiber is 70/70. 3
A mold base material in which the front and back surfaces of a mold base material made of a mixed material adjusted to a range of 0 to 40/60 are covered with a breathable cloth made of thermoplastic fiber and covered with the cloth. Are heated and pressed to be integrally molded.

[0008] As described above, by covering the mold base made of the mixed material of the plant fiber and the thermoplastic fiber with the cloth material of the thermoplastic fiber, the mold material having excellent surface water resistance and peelability as described above. Can be formed. In addition, if the mold base material covered with the cloth is preheated and then heated and pressurized and integrally molded, the mold base material can be preheated uniformly in a short time while preventing mold collapse, and energy efficiency during molding can be improved. Can be increased.

[0009] As the preheating means, it is possible to heat the mold base material covered with the cloth-like material using an electromagnetic wave heater or by blowing heated air. The plant fiber is mainly composed of cellulose, and is obtained by finely pulverizing or dry defibrating at least one of wood, plant, pulp, and waste paper. As the thermoplastic fiber of the mold base material, a polyester fiber, a polyamide fiber, a polyolefin fiber, or a composite fiber obtained by combining two or more kinds of polystyrene fibers cut into an arbitrary length of 5 mm to 20 mm is used. I do. The mixed material is made of one of polyester fiber, polyamide fiber, and polyolefin fiber, and has an air permeability of 50 cc at a wind pressure of 200 Pa.
/ cm ² · sec ~ 300cc / cm ² · sec Laminate on a breathable cloth-like material and cover it with the same cloth-like material from above to prevent scattering of formwork material during preheating Then, when it becomes a form material, the cloth on both the front and back surfaces melts to form a resin layer. As a result, a mold material excellent in water resistance and releasability, in which both front and back layers are covered with resin, with a mixing ratio of thermoplastic fibers of 30 to 60% by weight, is obtained.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The configuration of the present invention will be described below in detail with reference to the accompanying drawings.

FIGS. 1A and 1B show a method of manufacturing a form member according to an embodiment of the present invention. As shown in FIG. 1 (a), the formwork plate of this embodiment has a ventilation base made of thermoplastic fibers on both front and back sides of a formwork base 1 made of a mixed material of plant fibers and thermoplastic fibers. A mold base material 1 covered with a cloth material 2 and covered with the cloth material 2 is integrally molded by heating and pressing, and as shown in FIG.
And the back layer 4 forms a continuous resin layer containing no fibers,
The inside 5 is one in which plant fibers and thermoplastic short fibers are completely integrated.

[0012] In the above method for producing a mold plate, the thermoplastic fiber is a fiber generally used for apparel and industrial purposes.
20 mm, preferably 5 to 15 mm, most preferably 5 to 1
Cut the fiber to a range of 0 mm. When the fiber is a cloth-like material, it can be used as a raw material by cutting into a predetermined length and then defibrating by a dry defibrating machine.

As the thermoplastic fiber of the mold base material, a polyester fiber, a polyamide fiber, a polyolefin fiber, or a composite fiber obtained by combining two or more kinds of polystyrene fibers is used. The mold material made from these fiber materials can be crushed after use and reused as a material for the mold material. If it cannot be reused, waste paper and waste plastic fuel (RPF: Refuse Paper and Plastic)
It is suitable because it can be used for heat recycling as fuel and does not generate dioxin and the like when burned. Normal,
In the case of a cloth-like material, fibers having different melting points are mixed or vegetable fibers are mixed in most cases. Even if fibers having different melting points are mixed, even if most of the fibers are melted and some of the fibers remain, an effect similar to that of FRP can be obtained.
In addition, there is no problem because the mixed amount of the plant fiber may be subtracted from the input ratio of the plant fiber described later.

[0014] A long thermoplastic fiber length is good for improving the strength and toughness, but it is not divided into single pieces but is collected and dispersed as fiber balls. But a disadvantage. If the length is too short, the dispersibility is improved, but the number of contact points decreases, and the effect of improving strength and toughness decreases. When the fiber length is 5 to 20 mm as described above, the dispersibility is good, and the fiber exhibits a reinforcing effect when it is used as a formwork material. As the cutter, any cutter such as a spiral cutter and a guillotine cutter may be used as long as the fiber can be cut to a predetermined length.

The cut fibers have a water adhesion rate of 5%.
It is desirable that it be dried to within%. If it contains a lot of water, the fibers will stick together and will not separate,
When formed into a frame material, unevenness may occur, which may adversely affect strength and the like. If it is not wet, it does not need to be dried and may be omitted.

The short thermoplastic fibers can be separated by friction between the rotor and the barrier or by turbulence of high-speed air. Further, in some cases, the fiber separation operation may be performed at the time of mixing with the plant fiber fibrillation raw material. Either way, any method can be used as long as it can be separated.

If the thickness of the fiber used here is too large, stress concentration occurs at the fiber portion when the product is made into a product plate, and that portion may become a defect. The fiber diameter is desirably 10 μm to 70 μm because the fiber ball may be formed.

If the content of the thermoplastic short fibers in the form material is less than 30% by weight, the binding structure in the form material is not sufficiently formed, which adversely affects properties such as bending strength. If it exceeds 60%, no further reinforcing effect is seen, and the amount of plant fiber used is limited.
0% or more and 60% or less are preferable.

On the other hand, virgin pulp is most preferable in terms of performance as the vegetable fiber raw material used in the present invention. However, since the protection of timber resources has been called for in terms of the global environment, crushed used wood, other crushed plants, defibrated waste paper, and defibrated plant fibers such as cotton and hemp have been used. It is preferably used. Virgin pulp can be used as it is, but pulverized wood and plant pulverized matter can be preferably used as a raw material for a mold material after being fibrillated by dry fibrillation. In the recycling of waste paper, O
Not only high-quality paper such as A paper, but also newspapers, magazines such as weekly magazines, and recycled waste paper such as corrugated cardboard can be used as a raw material for formwork by simultaneously pulverizing them without separation and then dry-fibrillating them into fibrous form. Although it is possible, magazines such as newspapers and weekly magazines are more preferable as the raw material of the formwork material.

The front and back surfaces of a mold base made of a mixed material in which the mixing ratio of the plant fiber and the thermoplastic fiber obtained as described above is adjusted to be in the range of 70/30 to 40/60 by weight, is determined. It is covered with a breathable cloth made of one of plastic fibers, for example, polyester fibers, polyamide fibers and polyolefin fibers. Since the cloth-like material in which two or more kinds of fibers are mixed has a different melting point, the surface is not covered with a uniform resin film and the effect on water is reduced by half. The cloth used here may be any type of woven fabric, nonwoven fabric and knitted fabric.
The air permeability of the cloth at a wind pressure of 200 Pa is 50 cc / c.
m ² · sec to 300 cc / cm ² · sec, preferably 50 cc / cm ²
-If it is less than sec, it takes too much time to preheat with hot air, which is uneconomical. Also, if the air flow rate is too large, there is a possibility that the mold material may fly or be biased by the hot air through the eyes of the cloth. The basis weight of the cloth is 50 g / m ^{2 to} 150 g
/ M ² is desirable. If it becomes lighter than 50 g / m ^2, it will break,
The resin layer on the surface is too thin and loses its water resistance effect.
If the weight is more than / m ² , the surface resin layer becomes too thick, and the water resistance effect is saturated and does not change. The temperature and the flow rate of the hot air may be appropriately selected depending on the mixing ratio and the type of the material.
What is necessary is just to be able to preheat to a temperature of 200C. If the temperature is lower than 100 ° C., the preheating effect is small, and if it is higher than 200 ° C., the waste paper defibrated material is thermally degraded.

On the other hand, an electromagnetic wave heater can be used for preheating the form base material. There is an advantage that the heating time can be shortened because the heated object itself becomes a heating element by passing the mold base material covered with a cloth material made of thermoplastic fiber on both front and back sides through an electromagnetic wave heater. High energy efficiency. When heating is difficult, it is also a good method to add a small amount of a dielectric (for example, ceramic powder or the like) to the mold base material. In the case of performing electromagnetic wave heating, there are two types, microwave and high frequency, but may be selected according to the installation location, the mixing ratio of the materials, and the type of thermoplastic fiber, and there is no particular limitation. Moreover, you may use together with hot air heating. By hot-pressing the mold base material preheated to a predetermined temperature of 100 ° C. to 200 ° C. together with the cloth, the cloth on the front and back is melted and the front and back are covered with the resin film. . 100 ° C-20
By applying a pressure of 1 MPa to 5 MPa to the mold base material preheated to 0 ° C., an internal structure in which the fibrillated plant fibers and the thermoplastic fibers are firmly adhered to each other is formed, and the surface thereof is formed of a cloth-like resin. To form an integral form material covered with.

[0022]

EXAMPLES Examples of the present invention will be described below, but the present invention is not limited to these examples.

Example 1 Melt blown fiber waste made of polypropylene resin as a thermoplastic fiber and tow waste of polyethylene terephthalate fiber (5 denier) were each cut to a length of 10 mm with a guillotine cutter to obtain a raw material of a mold material. did.

Newspaper as a vegetable fiber raw material is put into a crusher and crushed to about 4 cm.
By putting it into a fibrillation machine with a rotor blade of about 0 RPM,
It was defibrated by frictional destruction with the wall and used as a raw material for formwork. Drying was omitted because the cut thermoplastic fiber (polypropylene fiber, polyethylene terephthalate fiber) and the waste paper disintegrated material were separated.

Each of these raw materials is in a weight ratio of 40: 1.
Measure to 0:50, put into a mixer and add 200 at room temperature.
By stirring at a rotation of about RPM, the thermoplastic fibers were separated and mixed with the used paper disintegration raw material to form an integrated structure.
A predetermined amount of the mold material is integrally measured, and the material is uniformly laminated on a breathable cloth made of polypropylene fiber having an air permeability of 200 cc / cm ² · sec at a wind pressure of 200 Pa. The same cloth was covered from above and the sides were sealed with weights to prevent leakage.

Next, hot air of 165 ° C. was blown for 5 minutes, and then introduced into a hot-press machine, molded at 165 ° C. under a hot-press condition of 0.98 MPa, gradually cooled, taken out, and defibrated with newspaper and thermoplastic fiber. Were integrated to obtain a fiber reinforced resin plate whose front and back surfaces were covered with resin.

Example 2 The conditions were the same as in Example 1 except that preheating was performed by a microwave heater instead of hot air.

Comparative Example 1 The same raw material as in Example 1 was directly set in a hot press machine without using a cloth material made of polypropylene and without preheating, and the same hot press machine was used for one hour under the same temperature and pressure conditions. A fiber reinforced resin plate was produced by applying the pressure.

COMPARATIVE EXAMPLE 2 An attempt was made to preheat the same raw material as in Example 1 without the cloth material on both the front and back sides. However, the raw material of the form material flew or collapsed in both hot air and microwave heating. The fiber reinforced resin plate could not be made.

For the samples of Examples 1 and 2 and Comparative Example 1,
The thickness, specific gravity, flexural strength, and water absorption thickness expansion coefficient were measured. The flexural strength was determined by the method of JIS A 1408.
0 cm). Water absorption thickness expansion coefficient is JIS A 59
Measured by method 05. Table 1 shows the measurement results. As can be seen from Table 1, Comparative Example 1 has a water absorption thickness expansion coefficient value that is 3 to 5 times higher than Examples 1 and 2, and Examples 1 and 2 show good resistance to water. Was.

[0031]

[Table 1]

[0032]

As described above, according to the present invention, when a form material is obtained by using a fibrillated fibrous raw material and a cut thermoplastic fiber material, the botanical fiber and the thermoplastic fiber are mixed and integrated. The mold base material of the configuration, the front and back surfaces are covered with a cloth made of thermoplastic fiber, and are integrally molded by applying heat and pressure. Formwork material can be obtained. In addition, if the mold base material covered with the cloth is preheated with hot air or electromagnetic waves and then heated and pressed to form a single piece, the mold base material can be preheated evenly in a short time while preventing mold collapse. Energy efficiency at the time can be improved.

[Brief description of the drawings]

FIGS. 1A and 1B show a method of manufacturing a mold material according to an embodiment of the present invention, wherein FIG. 1A is a cross-sectional view of a mold base material covered with a cloth material, and FIG. It is sectional drawing of a frame material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Formwork base material 2 Cloth material 3 Surface layer 4 Back layer 5 Inside

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) // B28B 7/34 B28B 7/34 FM (72) Inventor Eizo Goto 1-1-1, Oe, Otsu City, Shiga Prefecture No. 1 In the Seta Plant of Toray Industries Co., Ltd. (72) Inventor Akira Miyamoto 1-1-1, Oe, Otsu-shi, Shiga Prefecture In the Seta Plant of Toray Industries Co., Ltd. (72) Inventor Mitsuyuki Okano 1 Moto-Akasaka, Minato-ku, Tokyo 2-7-7 Kashima Construction Co., Ltd. (72) Inventor Takeo Kikuchi 1-2-7 Moto-Akasaka, Minato-ku, Tokyo Inside Kashima Construction Co., Ltd. (72) Katsunori Nishida 2-chome Tsukuda, Chuo-ku, Tokyo 17-15 Tsukishima Machinery Co., Ltd. (72) Inventor Takumi Kaneko 2-chome, Chuo-ku, Tokyo 2-17-15 Tsukishima Machinery Co., Ltd. F-term (reference) 3B154 AA02 AA07 AA08 AA09 AA12 AA16 AB19 AB22 BA47 BA60 B B02 BB12 BB22 BB54 BB66 BC41 BF30 4G053 AA07 BB17 CA20 4L047 AA08 AA14 AA21 AA28 AB02 BA09 BA23 BB02 BB06 CA01 CB10 CC13 EA10 EA11

Claims (8)

[Claims] 1. A mold material comprising a plant fiber and a thermoplastic fiber as main raw materials, wherein both front and back layers are covered with a thermoplastic resin and integrally formed. 2. A mold base made of a mixed material in which a mixing ratio of a vegetable fiber and a thermoplastic fiber is adjusted to be in a range of 70/30 to 40/60 by weight. A mold base material covered with the air-permeable cloth material, and the mold base material covered with the cloth material is heated and pressed to be integrally molded. 3. The method according to claim 2, wherein the mold base material covered with the cloth-like material is preheated, then heated and pressed to be integrally molded. 4. The process for producing mold material according to claim 2 or 3 aeration is ^{50cc / cm 2 · sec ~300cc /} cm 2 · sec in wind pressure 200Pa of the cloth-like material. 5. The mold according to any one of claims 2 to 4, wherein the plant fiber is obtained by finely pulverizing or dry defibrating at least one of wood, plants, and waste paper in which the main fiber component is cellulose. Manufacturing method of frame material. 6. The thermoplastic fiber of the form base material according to claim 2, wherein the thermoplastic fiber is at least one type of short fiber among polyester fiber, polyamide fiber, polyolefin fiber and polystyrene fiber. Manufacturing method of formwork material. 7. The method according to claim 2, wherein the thermoplastic fiber of the cloth-like material is one of a polyester fiber, a polyamide fiber, and a polyolefin fiber. 8. The method according to claim 2, wherein the mixing ratio of the thermoplastic fibers in the mold material is 30 to 60% by weight on a dry basis.