JP2002294580A - Method for producing foam molded article, method for producing laminated foam molded article and foam molded article produced thereby - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foam molded article for the production of a paper-based cushioning material having excellent elastic property and composed of regenerated organic fibrous material such as waste paper, a laminated foam molded article produced by laminating paper, etc., to the foam molded article, an apparatus for the production of the article and a method for producing the article. SOLUTION: The production facility for the foam molded article is provided with a kneading machine to knead a fibrous material and an aqueous solution to produce a kneaded mixture, a foaming machine to expand the kneaded mixture and produce a foamed article, a molding machine to mold the foamed material to a plate form and a drier to dry the foam molded article. The molding machine is provided with a nozzle to extrude the foamed material through the extrusion port toward the upper face of a molding plate substrate, the plate substrate is horizontally transferred relative to the nozzle and the width of the extrusion port of the nozzle is nearly same as the width of the plate- formed foam molded article. The invention further discloses a foam molded article laminated with paper, etc., and a method for producing the article.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for producing a foamed molded article, and more particularly to an apparatus for producing a foamed molded article and a method for producing a laminated foamed molded article which are suitably used for recycling fibrous substances such as waste paper. And a foam molded article obtained thereby.

[0002]

2. Description of the Related Art At present, a paper-based cushioning material obtained by recycling waste paper has attracted attention as an environmentally friendly cushioning material instead of a plastic-based cushioning material represented by styrene foam, which is widely used. Japanese Patent No. 3038158 discloses a paper-based cushioning material having excellent elasticity and a method for producing the same for the purpose of recycling waste paper. A method and an apparatus for manufacturing the method are disclosed in Japanese Patent No. 3017716. Japanese Patent No. 3038158 and Patent No. 30
The buffer material disclosed in Japanese Patent No. 17716 is manufactured by mixing waste paper powder, water, a binder containing 50% by weight or more of gelatin, a crosslinking reaction accelerator and a softening agent, foaming the mixture, and then molding and drying. It is stated that
Neither of the publications specifically describes a manufacturing apparatus or a manufacturing process in all processes from manufacturing waste paper as a raw material to manufacturing a cushioning material for a product. In particular, Patent No. 303815
Although the method of manufacturing a cushioning material specifically disclosed in Japanese Patent Publication No. 8 describes the composition and blending of raw materials, there is no specific description of a manufacturing process of kneading, foaming, molding, and drying. Although a general method for drying is mentioned, specific conditions are not disclosed. Foaming,
Regarding the molding, it was described that foaming and molding were performed in the mold pad, and gelatin could be dissolved by heating and drying.
It is merely described that the temperature is desirably lower than 0 ° C. and drying is required for several days, and a technique suitable for industrial production has not yet been achieved. Japanese Patent No. 3017716 describes operating conditions of a foaming machine used for foaming a kneaded material, but does not mention molding and drying methods and processes important for producing a foam molded article. Not been. As described above, in the prior art, not only is the basic process of what kind of manufacturing method can be used to obtain a foam molded article as a product, but also an entire manufacturing apparatus that can be industrially and economically manufactured continuously and Nothing is specifically described about the entire manufacturing process.

[0003]

DISCLOSURE OF THE INVENTION The present invention has been made in view of such conventional problems, and has been developed for a raw material comprising a fibrous substance and an aqueous solution, which has not been clarified so far. As a basic process of production until obtaining, it provides a manufacturing device consisting of kneading, foaming, molding and drying, a process and a method for producing kneading and foaming, and specifically provides a method and conditions for drying a molded foam. I do. This makes it possible to produce a foamed molded article such as a cushioning material having excellent elasticity performance from a fibrous substance, and in particular, to improve biodegradability and biodegradability by using a fibrous substance such as used natural paper as a raw material. An object of the present invention is to provide a manufacturing apparatus and a manufacturing method thereof capable of economically and continuously mass-producing an eco-friendly foam molded article having the same. Further, the present invention provides a method for producing a plate-like foamed molded article having a wide width and a uniform thickness, without generating avatar-shaped depressions on the surface and without impairing the appearance as a product. Cavities are hardly generated in the inside, the strength of the foam molded body can be increased, and further,
By lowering the specific gravity of the foam molded body and improving the yield in the production of cushioning materials with excellent elasticity,
An object of the present invention is to provide an apparatus and a method for producing a foamed molded article which can be mass-produced economically and continuously, and a foamed molded article produced thereby.

[0004]

SUMMARY OF THE INVENTION The present invention relates to a kneader for kneading a fibrous substance and an aqueous solution to produce a kneaded product, and a foaming machine for producing a foamed product by foaming the kneaded kneaded product. ,
A molding machine for producing a molded article by molding the foamed foam into a predetermined shape, and a foam molding article manufacturing apparatus provided with a dryer for drying the molded article; and a fibrous substance and an aqueous solution. A kneading step of kneading the mixture to produce a kneaded product, a foaming step of foaming the kneaded product kneaded in the kneading step to produce a foam, and forming the foamed product foamed in the foaming step into a predetermined shape. The present invention relates to a method for producing a foamed molded article, comprising: a molding step of producing a molded article by drying the molded article; and a drying step of drying the molded article formed in the foaming step at a drying temperature of 60 to 150 ° C. Further, the present invention provides a kneading machine for kneading a fibrous substance and an aqueous solution to produce a kneaded product, a foaming machine for producing a foamed product by foaming the kneaded kneaded product, and a foamed foamed product. In a molding machine for producing a plate-shaped foam molded article by molding into a plate, and a foam molded article manufacturing apparatus including a dryer for drying the foam molded article, the molding machine, via an extrusion port A nozzle for extruding foam toward the upper surface of the plate-shaped substrate for molding, wherein the plate-shaped substrate and the nozzle move relatively horizontally, and the extruding opening of the nozzle is formed. The width of the foamed molded article is at least substantially the same as the width of the plate-shaped foamed molded article, and a kneaded product is produced by kneading a fibrous substance and an aqueous solution. Kneading machine, and foaming for producing a foam by foaming the kneaded material. And a molding machine for producing the plate-like foam molded article by molding the foamed foam into a plate, and a dryer for drying the foam molded article. The machine has a nozzle portion having a size substantially equal to the width of a plate-like foam molded body that extrudes a foam toward an upper surface of a plate-like substrate for molding through an extrusion port. An operation of manufacturing a plate-like foamed molded article by relatively moving the nozzle portion in the horizontal direction, once drying the plate-shaped foamed molded article, and further extruding a foam on the upper surface of the plate-shaped foamed molded article. The present invention relates to a foamed molded article characterized by producing a laminated foamed molded article having a predetermined thickness by repeating the above steps, and a method for producing the same.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Examples of the fibrous substance used in the present invention include waste paper such as newsprint, magazines and corrugated cardboard, wool fabric (wool waste), pulp sludge, glass fiber and the like, but are not limited thereto. It is not something to be done. The fibrous material to be kneaded with the aqueous solution is preferably finely defibrated by a dry defibrating machine such as a cutter or a mill, but is preferably prepared by previously forming a muddy state with water or wet defibrating in water. You may. For example, when used paper is defibrated by a dry defibrating machine, one obtained by defibrating the screen of the defibrating machine so as to pass through 1 to 15 mm, more preferably 1 to 5 mm can be employed. As the water used for the aqueous solution, industrial water, tap water, purified water, and the like can be used as appropriate. Further, the aqueous solution to be kneaded with the fibrous substance preferably contains at least a binder, and the binder is used for forming a good foam, and as the binder, natural gelatin, Examples include glue, alginic acid, and synthetic polyvinyl alcohol. These may be used alone or in combination of two or more.

As the kneader, for example, a kneader provided with a paddle stirrer or a screw stirrer, a screw kneader, or the like can be used. In particular,
For example, a kneader having a container, a stirrer attached to the container, a pump connected to the container, and a means for circulating the pump to the container can be used. That is, a uniform kneaded material can be obtained by extracting a part of the kneaded material with a pump and circulating the mixed material in a container while stirring and mixing the fibrous substance and the aqueous solution with a stirrer.

[0007] Examples of the agent appropriately mixed with the kneaded product of the present invention include a crosslinking accelerator and a softening agent. The cross-linking accelerator is used, if necessary, to stabilize the foamed form. Examples of the cross-linking accelerator include a cross-linking promoting enzyme represented by transglutaminase, aldehyde compounds such as formalin, acetaldehyde, glutaraldehyde, and complex salts. Alum (potassium aluminum sulfate). These may be used alone or in combination of two or more. Also,
The softening agent is used to give elasticity to the molded body. As a softening agent, glycerin, ethylene glycol, diethylene glycol, polyethylene glycol,
Examples thereof include triethanolamine, polyvinyl alcohol, and the like, or those obtained by adding sucrose to any of these. These may be used alone or in combination of two or more. Further, the agents appropriately mixed with the kneaded materials other than those described above include release agents, surfactants, antibacterial agents, antifungal agents, coloring agents, bleaching agents, antioxidants, weather (light) agents, flame retardants , Fillers and the like.

[0008] The method of kneading the fibrous substance and the aqueous solution is as follows.
Even if the whole amount of the fibrous substance is mixed and kneaded with the aqueous solution at a time, a part of the fibrous substance may be mixed with the aqueous solution, and then the remaining fibrous substance may be mixed and kneaded. It is preferable to fill an aqueous solution containing at least a binder, and gradually add and knead the aqueous solution while stirring the fibrous substance in the aqueous solution, because it is possible to uniformly and easily knead the mixture with a small amount of water and a small amount of the binder. . Further, when a fibrous substance is mixed with water containing no binder, the water content of the kneaded material increases, the drying time becomes longer, and the amount of the binder used also increases. For example, when the used paper is kneaded with water alone, the water content of the kneaded material is 90% by weight or more, and in the aqueous solution containing the binder, the water content of the kneaded material is about 70% by weight. The time during which the obtained kneaded material is supplied from the kneader to the foaming machine is preferably within one hour so that the foamed state of the kneaded material is maintained. If the time exceeds 1 hour, the kneaded material tends to be defoamed. Further, the solid concentration of the kneaded material is usually 10 to 40% by weight,
Preferably, it is about 15 to 30% by weight. If the solid concentration of the kneaded material is lower than 10% by weight, the water content increases, drying takes time, and the energy cost increases,
If the content is higher than 40% by weight, the solid concentration becomes too high, the fluidity is lost, and the transfer by a pump or the like becomes difficult.

As the foaming machine, for example, a foaming machine for foaming only with a kneaded material, an air-mixing foaming machine for foaming while mixing air, a foaming agent-mixing foaming machine for adding a foaming agent to the mixture and foaming it, etc. are appropriately used. Can be adopted. The pressure in the foaming machine and the air-mixing foaming machine is usually
0.1 to 0.5 MPa, preferably 0.2 to 0.5 MPa.
0.4 MPa. When the pressure is lower than 0.1 MPa, the air is not sufficiently mixed, so that the foaming is insufficient, the specific gravity of the molded body is increased, and an avatar-shaped depression is easily generated on the surface. If the pressure is higher than the above range, the pressure change is large and rapid expansion occurs, so that an avatar-shaped depression is easily generated on the surface of the foamed molded product of the product as described above, and the appearance defect rate is increased. The mixing ratio of air in the air mixing and foaming machine is usually 1 kg / min for the kneaded material.
0.1 to 2 NL / min, preferably 0.6 to 1 N
L / min. When the mixing ratio of air is less than 0.1 NL / min, the amount of air is too small and foaming becomes insufficient, and the specific gravity of the molded body becomes heavy. On the other hand, when the mixing ratio is more than 2 NL / min, fine bubbles are caught. In addition, the porcelain dents cannot be formed, and avatar-shaped depressions are likely to be generated on the surface of the foam molded article of the product. A specific method of foaming the kneaded material is to apply a predetermined pressure (for example, 0.2 MPa or more) to the kneaded material, and to set a temperature at which the binder such as gelatin does not solidify and does not deteriorate (for example, 50 to 70 ° C.). A predetermined peripheral speed (for example,
4m / s or more) with continuous stirring and mixing.
A gas supply device (for example, air) is forcibly fed and foamed. The foaming specific gravity of the mixture in the foaming machine is preferably 0.15 to 0.45 g / cm ³ (FIG. 8).
reference). If the foaming specific gravity is lower than 0.15 g / cm ³ , the strength of the molded article after drying becomes too weak.
When it is higher than 45 g / cm ³ , the specific gravity of the molded body becomes heavy, and when it is used as a cushioning material, the cushioning effect becomes low. The specific gravity of the molded body after drying is preferably as low as possible,
By setting the foaming specific gravity as described above, absolute dry specific gravity (specific gravity at a constant temperature under conditions of a temperature of 80 ° C. and a relative humidity of 7 to 8%)
Is about 0.06 to 0.16 g / cm ³ , and a good product having relatively high strength of the foamed molded article can be obtained.

In order to continuously perform the kneading step and the foaming step, two kneaders may be provided, and the kneaded material may be alternately supplied from each kneader to the foamer. Alternatively, an intermediate slurry tank for temporarily storing the kneaded material may be provided, and it is preferable that the intermediate slurry tank is provided with a stirrer for keeping the foamed state of the kneaded material. Furthermore, a plurality of foaming machines provided in the foaming step are connected in series, and the various raw materials are continuously supplied to the foaming machine at the first stage, while performing a kneading operation as slowly as possible so that air is not mixed. Alternatively, the foaming operation may be continuously supplied to the subsequent-stage foaming machine, and the foaming operation may be performed in the final-stage foaming machine.

As the molding machine, for example, various kinds of general-purpose extrusion molding machines for extruding the obtained kneaded material from a die with a screw and cooling or heating and solidifying the kneaded material, and injecting the kneaded material into a mold through a nozzle by a cylinder. And
It is also possible to employ an injection molding machine or the like which cools or solidifies by heating in this mold. Further, the molding machine has a nozzle portion for extruding a foam toward an upper surface of a plate-shaped substrate for molding through an extrusion port, and the plate-shaped substrate and the nozzle portion are relatively horizontally moved. Move, the width of the extrusion port of the nozzle portion is at least approximately the same size as the width of the plate-shaped foam molded article, extrudes the foam from the extrusion port onto the plate-like substrate, the width of the extrusion port is It is sufficient that the width is at least substantially the same as the width of the plate-shaped foam molded body, and it is preferable that the nozzle is a divergent nozzle toward the extrusion opening having a predetermined thickness. Can be. In addition, as the divergent nozzle, a pentagonal shape, a triangular shape, a base shape, and the like can be given as the front shape. Also,
By forming a shape in which a plurality of divergent nozzles are connected in the width direction toward the extrusion opening having a predetermined thickness, an extremely wide foam molded article can be manufactured at a time, and productivity is improved. Further, the elevation angle α of the divergent nozzle (the angle of the top on the foam supply port side, see FIG. 2) is 30.
８５85 degrees, preferably 40-60 degrees. Elevation angle is 3
If it is smaller than 0 degree, the height of the nozzle portion becomes too high,
The foam may be solidified in the middle, while if it is larger than 85 degrees, the shape of both sides may be irregular. In addition, since the foam supply port side of the nozzle part for extruding the foam of the molding machine is directly connected to the foaming machine, the foaming machine used in the conventional apparatus for producing a synthetic resin molded article or molded food is used. A fixed amount slurry pump or the like in connection with the molding machine can be eliminated.

It is preferable that a flattening plate for smoothing the surface of the extruded foam molded article and for adjusting the thickness in cooperation with the nozzle section is provided on the nozzle section. The thickness of the foam molded article can be arbitrarily controlled by adjusting the height and the leveling plate in cooperation with each other. In addition, since the cross-sectional shape of the extrusion opening in a plan view or the lower surface of the leveling plate has a continuous triangular shape, the surface area is large, so that drying is easy, and two of the obtained foamed molded products are coated on the surface. By stacking these continuous triangular shapes, it is possible to easily produce a laminated body having high strength because it is difficult to shift and the impact is dispersed.
When the extrusion port has a cross-sectional shape in a plan view or the lower surface of the leveling plate has a corrugated shape, the surface area is large, so that drying is easy, and the obtained foam molded article has strength because the impact is dispersed. Good.

It is preferable that at least the upper surface of the plate-like base material for molding is processed with a synthetic resin. Examples of the synthetic resin include a fluororesin such as polytetrafluoroethylene;
Examples include polypropylene, polyethylene, and silicone rubber. The synthetic resin processing includes, for example, a method in which a glass sheet or a net-like sheet impregnated with a synthetic resin is adhered to at least the upper surface of a plate-shaped substrate. As a plate-like base material, an iron material frame is good,
Aluminum is preferred from the viewpoint of weight reduction and the like. By using the plate-shaped substrate processed with the synthetic resin as described above, the peel strength (force required for peeling) of the foam molded article can be reduced. For example, the peel strength in the case of only an aluminum plate-shaped base material is about 4 kgf or more per 300 mm width, but in a plate-shaped base material on which a glass sheet impregnated with a fluororesin is stuck, 2 kgf, a polypropylene net is stuck. The weight of the attached plate-like base material was 1.7 kgf, indicating that the releasability was extremely improved.

[0014] A nozzle portion having a size substantially equal to the width of the plate-like foam molded body for extruding the foam toward the upper surface of the plate-like substrate for molding through an extrusion port is provided. After the plate-shaped foam molded article is once dried by a molding machine for manufacturing the plate-shaped foam molded article by relatively moving the nozzle portion in the horizontal direction, the foam is further extruded onto the upper surface of the plate-shaped foam molded article. By repeating the operation and manufacturing a laminated foam molded article having a predetermined thickness, a laminated foam molded article having an arbitrary thickness can be easily produced, and a drying time of the produced laminated foam molded article can be shortened. Further, a laminate having high adhesive strength can be manufactured without using an adhesive.

It is also preferable that a cloth is laid on the plate-like base material and a foam is extruded thereon. When the foamed molded article is integrally laminated and formed on the cloth as described above, after the plate-shaped foam is dried, the plate-shaped foam is easily peeled off from the plate-shaped base material, and the strength of the plate-shaped foam is improved. here,
The shape of the fabric may be a flat plate or a corrugated shape. In the case of using a fabric having an uneven shape, a foam is extruded thereon, and is coated to a thickness exceeding the height of the convex portion of the uneven shape. As the cloth, any material may be used as long as it belongs to the concept of a cloth, such as a woven fabric or a knitted fabric, in addition to a nonwoven fabric such as a paper or a backing paper. However, a paper or a backing paper is preferable because it can be supplied at low cost. As the paper, any paper such as kraft paper and trim paper may be used. In addition, as mount, single cardboard
Any mount may be used. In the case of using paper, if it is used in a dry state, wrinkles, warping, warping, and the like are likely to occur in the obtained foamed molded article due to the moisture of the foamed material. In this way, by pre-wetting the paper with water, the water content of the foam and the paper becomes almost the same, and by drying from the same water content, wrinkles, more warping, etc. of the obtained foamed molded article are reduced. Can be prevented. Here, in order to make the paper wet in advance, the paper may be laid on a plate-shaped body, and the paper may be wetted on the paper using a water supply means such as a shower. In addition, the fabric such as the paper was not only laid on the plate-shaped body, but also separately laminated in an in-line manner on the top of the extruded foam, and the fabric was laminated on both sides of the plate-shaped foam. Alternatively, a sandwich structure may be employed.

As described above, the cloth such as paper is laid on the plate-like base material, the foam is extruded thereon, and the fabric and the foam are naturally formed in the drying step by utilizing the self-adhesiveness of the binder. First, the peel strength between the plate-shaped base material and the obtained foamed molded article can be significantly reduced by forming the bonded and solidified foamed molded article, and the foamed molded article can be peeled more easily than the conventional method. It is possible to do. Incidentally, the peel strength of the foam molded article when directly extruding the conventional foam into the plate-like body is about 2 kgf, but when laminating a cloth such as paper, the peelability is remarkably about 0.5 kgf. improves. In addition, since the foam contains a binder, the foamed molded article naturally adheres to and hardens with a cloth such as paper in the drying step, so that there is no need to use an adhesive such as glue. Further, since the obtained foamed molded article is formed by laminating a cloth such as paper, the strength of the material against bending and pulling is improved, and the workability and quality of the product are improved. For example, since the composite is formed by laminating a cloth such as paper, the strength of the material is improved as compared with the conventional single material, and the peeling becomes easy even when peeling off from the plate-like body. In addition, when compounded with cardboard paper, the original cushioning effect (restorability) of the foamed molded article is added, and a cardboard composite material resistant to repeated drops can be obtained. Furthermore, when paper is laminated on the surface of the obtained foam molded article, unevenness does not occur on the surface, the surface becomes smooth, and the accuracy of thickness can be improved. Furthermore, when it is desired to use the foam of the present invention itself as a wrapping material by thinning the foam itself, the foam itself has a low strength and breaks immediately, but when a mount is used together, this is used as a reinforcing material. The effect is also achieved, the strength is increased, and the handleability when using the obtained foam molded article in a product is remarkably improved. In addition, the use of the backing sheet is rich in water absorption, so that the residual moisture of the foam is absorbed,
The drying time can be significantly reduced as compared with the case where no mount is used.

Furthermore, when the mount having the uneven shape is used, the contact surface between the foam and the uneven shape such as the wavy shape is increased as compared with the flat shape, and the drying time can be drastically reduced.
In addition, the amount of foam used in the portion corresponding to the corrugated cross-sectional area is saved, and the drying time is reduced by the cost and the saving of the used volume. Furthermore, since it is possible to enjoy the cushioning property of the wavy itself in combination, by changing the irregular shape such as the wavy shape, it is an eclectic cardboard card having a unique cushioning property that cannot be obtained with a foamed molded article made of a foam alone. A foam molded article of the type is obtained.

The method of forming the plate-like molded body is not limited to the above-mentioned method. For example, the foamed product from the above-mentioned molding machine used in the present invention is firstly removed from an endless mold having releasability. Extruded on a belt to form a plate-shaped molded body, then, cool air is blown onto the surface of the plate-shaped molded body, dried or solidified, and further placed on the plate-shaped substrate in a reversed state. Is also good. Here, as the endless belt, a material having releasability, such as silicone rubber or polytetrafluoroethylene coated rubber belt, is used. By cooling and / or drying the surface of the plate-shaped molded product formed on the endless belt with cold air, the plate-shaped molded product is dried and / or solidified, and the releasability is improved. As conditions for the cold air treatment, the temperature is 10 to 20 ° C., and the air volume is about 4 to 10 Nm ³ / kg with respect to the weight of the molded body before drying. Next, the plate-shaped formed body placed on the endless belt is placed on the plate-shaped substrate used in the present invention in a state where the belt is inverted,
Thereafter, it may be conveyed to the drying step according to the above-mentioned manufacturing method. If molding is performed by this method, the surface can be placed on a plate-like substrate in a state where the surface is slightly dried or solidified,
For this reason, the adhesiveness with the plate-shaped substrate in the drying step can be reduced,
Accordingly, the releasability of the dried foamed article from the plate-like substrate (tray) is improved. As a result, the labor of the product peeling operation is reduced, and the occurrence rate of defective products can be reduced.

In the molding machine used in the manufacturing method of the present invention described above, foreign matter tends to accumulate in the dead space of the molding machine during operation, and the quality of the product is degraded due to the inclusion of such foreign matter in the foam. There is. In the conventional method for removing foreign substances in a molding machine, it is necessary to perform a labor-consuming operation of stopping the manufacturing apparatus, disassembling and cleaning the molding machine, and further, it is necessary to provide a washing mechanism for water washing and a drainage facility.
In the present invention, by extruding the unfoamed kneaded material into the molding machine, it becomes possible to flush out foreign matters staying in the molding machine. Even if the foam is extruded into the molding machine, the specific gravity of the foam itself is low and the foam has elasticity, so that foreign matters staying in the dead space in the molding machine cannot be washed away. According to the present invention, without stopping the apparatus, for example, by stopping the gas supply device of the foaming machine, and extruding the unfoamed kneaded material into the molding machine, it is possible to flush out foreign matter in the molding machine Become. According to this foreign matter removing method, the used unfoamed kneaded material can be recovered and used, and there is no waste. Therefore, as compared with the conventional foreign matter removing method by washing with water, there are advantages such as no increase in equipment cost, no increase in raw materials and utilities, and possible to remove foreign matter without stopping the apparatus.

Examples of the dryer include a shelf-mounted natural dryer for placing a molded article on a shelf and drying it naturally, a heating dryer for heating and drying the molded article by the heat of a heater, and a heating dryer for heating and drying with hot air. A hot-air dryer for drying, a reduced-pressure dryer for drying the drying chamber in a negative pressure state, a freeze-drying freeze dryer, or the like can be used. others,
A microwave irradiation dryer, a dehumidification dryer, or the like may be used. The drying temperature in the heating and drying is not more than 40 ° C. in the conventional production method because gelatin mixed as a binder is dissolved, but in the present invention, the production method is different, and The amount is large, the foam can be uniformly foamed, and gelatin mixed as a binder does not dissolve out.
0 ° C, preferably 70 to 100 ° C. When the drying temperature is lower than 60 ° C., it takes too much time for drying and the shrinkage of the foamed molded article is increased.
When the temperature is higher than ℃, the composition of various components contained in the foamed molded article changes, and the flexibility becomes low. As the dryer, a warm air dryer is preferable. When the warm air dryer is used, the warm air drying temperature is set to 100 ° C. ± 20 ° C.
The former drying (constant-rate drying) step of drying at 50 ° C. for 50 to 80% of the total drying time;
It is preferable that the drying is performed in a latter stage (drying-down drying) process in which drying is performed for a time period of 0 to 50%, and at least the hot air drying temperature in the latter stage is set to be lower than that in the former stage. If the pre-stage drying is performed at a low temperature other than the above range, it takes time to dry,
The shrinkage of the foamed molded article also increases, and when the foamed molded article is subjected to a high temperature, the composition of various components contained in the foamed molded article changes, and the flexibility decreases. When the latter drying is performed at a low temperature outside the above range, the drying takes a long time, and when the latter drying is performed at a high temperature, the composition of various components contained in the foamed molded article changes, and the flexibility is lowered. Furthermore, if the hot air drying temperature in the latter drying step is set to a higher temperature than in the former drying step, the drying efficiency is deteriorated only by a constant-temperature drying state in which the product temperature is slightly increased.

In the drying step, in addition to the above dryer, microwave drying can be used alone or in combination with a hot air dryer. The above-mentioned hot air drying is cheap in equipment, but the surface portion of the dried foamed product tends to solidify, while the drying of the central portion is slow, and the uniformity of the obtained product is not always good. On the other hand, according to the microwave drying, the surface portion and the central portion of the foam molded article are uniformly dried, so that the obtained product is excellent in uniformity. In the case of microwave drying, the microwave capacity is 0.7 to 2.5 kW / kg, preferably 0.5 to 2 kW, based on the weight of the molded body before drying.
/ Kg. If it is less than 0.7 kW / kg, the drying time is long, and the shrinkage of the foamed article after drying is large. On the other hand, if it is more than 2.5 kW / kg, the drying time is short, but Bulging, and the center may burn. When the microwave capacity is within the above range, the obtained foamed molded product does not have swelling, cracking, core burning, and has little shrinkage, so that the optimum microwave drying conditions are obtained. Further, as compared with the heating and drying, the dried binder and fiber are dried while being uniformly distributed. In the case of microwave drying, the initial stage of drying may be performed with a high volume, and after a while, the drying may be performed with a low volume in the later stage of drying. As described above, microwave drying and heat drying can be used in combination. In other words, in terms of equipment cost, heating and hot air drying is cheaper than microwave drying, so for example, start drying with microwave drying,
After the central portion is dried to some extent, hot air drying may be performed, or microwave drying and hot air drying may be performed simultaneously.

Hereinafter, an apparatus and a method for producing a foam molded article according to the present invention will be specifically described with reference to the drawings. Figure 1
FIG. 1 is an overall configuration diagram of an apparatus for manufacturing a foamed molded article according to an embodiment of the present invention. FIG. 2 is a perspective view illustrating a use state of a nozzle portion of a molding machine incorporated in the apparatus for manufacturing a foamed molded article according to the present invention. FIG. 3 is an enlarged view of a main part showing a state in which a foamable body is being molded by a molding machine, FIG.
(A) to (d) are front views of nozzles of various embodiments, and FIG.
(A) is an enlarged bottom view of a nozzle part having an extrusion opening having a continuous triangular shape, FIG. 5 (b) is a perspective view of a sheet-like foam molded article formed by the nozzle of FIG. 5 (a), and FIG. FIG. 6 is an enlarged bottom view of a nozzle portion having an extruding port having a continuous waveform.
6B is a perspective view of a sheet-like foam molded article formed by the nozzle of FIG. 6A, and FIG. 7 is a perspective view of a sheet-like foam molded article obtained by laminating a plurality of sheets.

In FIG. 1, reference numeral 10 denotes a production apparatus for producing a foam molded article which is a foam molded article from waste paper of a fibrous substance. This production apparatus 10 comprises a waste paper disintegrator 11 for defibrating the fibrous substance, A defibrated waste paper storage hopper 12 for temporarily storing defibrated waste paper, a kneader 13 for kneading the defibrated waste paper and various additive agents, and a chemical supply facility for storing and supplying the various additive agents to the kneader 13 14, an intermediate tank 15 for temporarily storing the obtained kneaded material, a foaming machine 16 for foaming the kneaded material, a molding machine 17 for molding the obtained foamed material into a sheet-like foamed molded product, A molded product conveyor 18 on which a tray, which is a resin-processed plate-shaped base material, is placed and on which the foamed article is carried out, a rack stacker 19 for stacking the ejected foamed article on a rack, and the foamed article is dried. Dryer for forming foamed products 0, and a foamed molded extruder 21 for extruding one by one rack stacked by product foamed molding. Note that a plurality of kneaders 13 may be provided without providing the intermediate tank.

The used paper defibrating machine 11 defibrate used paper such as newspaper, magazine, cardboard, etc. with a cutter or the like to obtain 1 to 15 mm.
This is a device that passes through a screen with openings to turn into defibrated waste paper. A cutting device 12a that supplies the defibrated waste paper to the kneader 13 is provided below the defibrated waste paper storage hopper 12. The kneading machine 13 is a device for kneading the defibrated waste paper from the defibrated waste paper storage hopper 12, water, and various chemicals from the chemical supply facility 14 to produce a kneaded material. Stirrer 1 attached to container 13a and various chemicals
3b, a pump 13c connected to the container 13a and provided at the lower part of the container, for transferring the kneaded material, and a circulation line from the pump 13c to the container 13a are provided, and an aqueous solution containing the defibrated waste paper and the medicine is provided. While stirring and mixing with the stirrer 13b, a part of the kneaded material is extracted by the pump 13c and circulated through the container 13a to produce a uniform kneaded material. As the pump 13c, a positive displacement pump generally used for a high viscosity mixture is employed.

The medicine supply facility 14 has a first hopper 14a for storing a binder and a second hopper 14a for storing a softening material.
And a third hopper 14 for storing a release agent.
c and a fourth hopper 14d for storing a crosslinking reaction accelerator
And a fifth hopper 14h for storing a preservative. A measuring tank 14e is provided between the hoppers 14a to 14h and the kneading machine 13, and the measuring tank 14e measures the injection amounts of various chemicals supplied to the kneading machine 13. In addition, the obtained foam molded product and the scraps of the dried product may be temporarily stored in the repulping tank 14f, and may be put into the kneading machine 13 by the pump 14g as a part of the defibrated waste paper. Alternatively, the obtained foamed molded product and the scraps of the dried product are defibrated by a used paper defibrating machine 11 and temporarily stored in a hopper 12, and as a part of the defibrated used paper, a kneading machine 13 is used.
May be charged.

The intermediate tank 15 is a tank for storing the kneaded material temporarily kneaded in order to continuously operate the foaming machine 16, and is stirred by a stirrer 15a, and the kneaded material is circulated by a circulation pump. Force circulation at 15b. Thereafter, the kneaded material is sent to the foaming machine 16 by the supply pump 16a to the foaming machine 16. In an apparatus in which no intermediate tank is provided and two kneaders 13 having substantially the same configuration as those described above are arranged, the production of the kneaded material, which takes more time than the foaming process, is performed alternately. Since the foaming machine is supplied to the machine, the foaming machine can be operated more reliably and continuously. The foaming machine 16 is an air mixer for producing a foamed material by forcibly blowing air into the kneaded material by an air supply device (not shown) and mixing. Here, the gas to be blown and foamed may be a gas under normal temperature and normal pressure, and may be, for example, nitrogen, carbon dioxide or a mixture thereof other than air.

The molding machine 17 is an extrusion molding machine for extruding a foam into a sheet shape.
b, a nozzle part 17a for extruding foam toward the upper surface of a tray, which is a plate-shaped base material for molding, and the molded article conveyor 18 and the nozzle part 17a relatively move in the horizontal direction, The width of the extrusion opening 17b of the portion 17a is at least substantially the same as the width of the plate-shaped foam molded article.
The molded article conveyor 18 has an aluminum tray on which a fluororesin impregnated glass sheet is adhered on the upper surface. The nozzle portion 17a has an extrusion opening 17b having a predetermined thickness.
4 (a) and 4 (b), the frontal shape is a base pentagon (a), and the shape (b) has an R shoulder. ), By forming a shape (c) in which a plurality of divergent nozzles are connected in the width direction and a triangular shape (d), a wide foam molded article can be manufactured at one time, and productivity is improved. Further, the elevation angle (α) of the divergent nozzle is
It is 30 to 85 degrees, preferably 40 to 60 degrees (FIG. 2).

The nozzle portion 17a is provided with a leveling plate 17d for smoothing the surface of the extruded foamed article and adjusting the thickness in cooperation with the nozzle portion 17a.
The height of the extrusion port 17b of the nozzle portion 17a and the leveling plate 17
The thickness of the foam molded article can be arbitrarily controlled by adjusting the height d in cooperation with the height d. FIG.
As shown in FIG.
By providing a shaping plate 17g having a continuous triangular shape on the inner surface of the top plate of FIG. 5B, a protruding ridge having a triangular cross section is continuous on the upper surface of the sheet in the width direction of the sheet, as shown in FIG. Can be produced. By laminating the two foam moldings S1 with the continuous triangular shape of the surface engaged and laminated, it is possible to easily produce a laminated body having high strength since it is hardly displaced and the impact is dispersed. Further, as shown in FIG.
By providing a shaping plate 17h having a corrugated shape in which a convex part is an acute angle and a concave part is gently curved on the inner surface of the front plate of the extrusion opening 17b of the 7b, the sheet is provided on the upper surface of the sheet shown in FIG. A foam molded article S2 having a shape in which the ridges having a circular arc cross-section are continuous in the width direction can be manufactured. This foamed molded article S2 has a large surface area, so that it is easy to dry. Further, the obtained foamed molded article has high strength because the impact is dispersed. The nozzle 17a
Is not limited to the shape described above.

The nozzle portion 17a is provided vertically above the downstream portion of the molded article conveyor 18, and more specifically, a pair of fixed frames 17 arranged horizontally above and below the surface side thereof.
c is supported in a vertical state. On the lower surface of the lower fixed frame 17c, a leveling plate 17d for leveling the foam extruded from the extrusion opening 17b is fixed in the horizontal direction. The surface of the foam can be smoothed by the leveling plate 17d. In addition, since the lower surface of the leveling plate 17d has a continuous triangular shape or a wavy shape, the surface of the foam is formed into a foam molded product having a shape in which triangular ridges are continuous or a ridge having a circular arc cross section. A foam molded article having a continuous shape can be manufactured. Further, a protrusion prevention plate 17e for preventing the foam from protruding is vertically arranged below the back surface of the nozzle portion 17a. The protrusion prevention plate 17e can prevent the generation of solid fibrous material due to the intrusion of foam.

The molded article conveyor 18 is an apparatus for carrying out the obtained foam molded article. The rack stacking machine 19 is a device for stacking the foamed molded products carried out from the molded product conveyor 18 on a rack. The dryer 20 is a hot air dryer. Specifically, it mainly has a drying chamber 20a and a hot air generator 20b which is a heat exchanger. Hot air generator 2
In 0b, the air blown by the fan 20c is heated by steam supplied through another path, and the obtained hot air is blown into the drying chamber 20a. As a result, the rack-shaped foamed molded body stored in the drying chamber 20a is dried. Drying room 2
At 0a, a circulation fan 20d for hot air and a fan 20e for exhaust are disposed. The foam molding extruder 2
1 extrudes the rack-shaped plate-like foamed molded products carried out from the dryer 20 one by one to the outside by an extrusion cylinder 21a and carries them out as a product.

Next, a method of producing a plate-like foam molded article by the foam molded article producing apparatus 10 will be described. First, the used paper defibrating machine 11 defibrate used paper such as newspaper, magazine, cardboard, etc., and the opening of the screen of the defibrating machine 11 is 1 to 15 mm.
Is supplied to the defibrated waste paper storage hopper 12 for storage. The defibrated waste paper is supplied from the defibrated waste paper storage hopper 12 into an aqueous solution containing at least a binder previously filled in the container 13a of the kneading machine 13 by the cutting device 12a, and the defibrated waste paper, the aqueous solution, While stirring and mixing with the various chemicals supplied by the agitator 13b, a part of the mixture is extracted by the pump 13c and circulated through the container 13a to produce a kneaded material.

Here, a specific example of a kneading method using 10 kg of defibrated waste paper as a raw material will be described. First, 69.7 kg of an aqueous solution containing 3.7 kg of gelatin as a binder from the first hopper 14a, 7.5 kg of glycerin as a softening material from the second hopper 14b, and the third hopper 1
0.03 kg of the release agent is supplied from 4c, and 37 g of potassium sorbate as a preservative is added and mixed from the fifth hopper 14h. The temperature at that time is 6
0 ° C. Thereafter, 10 kg of defibrated waste paper is put into the aqueous solution in the container 13a from the defibrated waste paper storage hopper 12, and the stirrer 13b is slowly stirred at 45 rpm for about 10 minutes, so that various chemicals are impregnated into the defibrated waste paper, The fibrillated waste paper is prevented from growing in a mountain shape in the container 13a.
After the supply of the various materials is completed in this way, the stirring speed of the stirrer 13b is increased to 90 rpm, and the various chemicals are used in the defibrated waste paper. This stirring time is about 3 minutes.

Next, the stirring speed of the stirrer 13b is set to 120r
pm, and start mixing with the defibrated waste paper and various chemicals. After about one minute, the pump 13c below the container 13a is activated. Thereby, circulation of the kneaded material is started to assist uniform mixing. In addition, the circulation rate of the kneaded material is 10 L / min. After stirring and mixing for about 10 minutes in this state, the crosslinking reaction accelerator 0.35
Supply kg. Further, the kneading step is completed by stirring and mixing for about 10 minutes. In this case, the supply order of the defibrated waste paper and the aqueous solution is reversed. Conversely, when the defibrated waste paper is supplied and the aqueous solution is supplied and kneaded, the defibrated waste paper adheres to the inner wall surface of the container 13a. And it is difficult to make it flow. As a result, a uniform kneaded product cannot be manufactured.

The obtained uniform kneaded material is temporarily stored in the intermediate tank 15 in order to continuously operate the foaming machine 16. Here also, the kneaded material is mixed by the stirrer 15a into one.
While stirring at a rotation speed of 5 rpm, the circulation pump 15
Forced circulation by b.

Thereafter, the kneaded material in the intermediate tank 15 is supplied to the foaming machine 16 by the supply pump 16a. In the foaming machine 16, air is forcibly blown into the kneaded material by an air supply device (not shown) to be mixed. This gives a foam. In the foaming step, air is sent to form uniform and fine bubbles. However, if the amount of air blown by the foaming machine 16 is excessively increased, the fine bubbles cannot be entrapped, and the surface of the foam molded product of the product may be reduced. It becomes avatar-shaped and has poor appearance. For this reason, by entraining air in the kneading process and limiting the amount of air blown in the foaming machine 16,
It is possible to manufacture a foamed product of a product containing good air bubbles. Therefore, here, the air blowing rate is set to 0.8 NL / min with respect to 1 kg / min of the kneaded material, and the foaming specific gravity of the mixture is set to 0.3 g / cm ³ .

The obtained foam is sent to a molding machine 17,
It becomes a sheet-like foam molded body by extrusion molding,
In this extrusion molding, the foamed material is extruded in a plate shape from the extrusion opening 17b of the nozzle portion 17a onto a tray placed on the molded product conveyor 18, and the foamed material that moves with the rotation of the molded product conveyor 18 is leveled by a flat plate 17d. By flattening, a plate-like foam molded article having a smooth surface can be obtained. At this time, by adjusting the height of the nozzle portion 17a and the leveling plate 17d from the tray, a plate-like foam molded body having a predetermined thickness can be obtained.

Further, after the plate-like foamed molded article produced as described above is once dried, the operation of extruding a foam on the upper surface of the plate-shaped foamed molded article is repeated to thereby obtain a laminated foamed molded article having an arbitrary thickness. Can be manufactured efficiently.
By manufacturing a thick foam molded article by the above-described method, even if the shrinkage rate differs between the central portion and the end portion, the shrinkage is small, so that a curved state due to slackness does not occur. afterwards,
The obtained foamed molded product is cut into a predetermined size, and is carried out by the molded product conveyor 18. This molded product conveyor 1
At the carry-out port 8, a large number of foam molded articles are stacked on a rack by the rack stacker 19. Product scraps generated at the time of cutting are temporarily stored in the repulp tank 14f,
Again, it is put into the kneading machine 13 by the pump 14g as a part of the defibrated waste paper.

[0038] The foamed molded products stacked in a rack are put into a box-shaped dryer 20. Here, hot air drying is performed at a constant temperature of 80 ° C. The drying time is 5 minutes when the thickness of the molded foam is 5
mm is about 3-5 hours, 10 mm is about 5-7
Time. If the temperature is about 110 ° C., drying is completed in about 2 to 3 hours with a 10 mm one. It is also effective to increase the wind speed, and if it is increased by 25% per 1 m / s, the drying time is reduced by about 1 hour. Although it depends on the properties of the foam, a difference in the drying temperature of 10 ° C. corresponds to a drying time of 1 hour. The drying temperature in this drying step is usually 60 to 15
0 ° C, preferably 70 to 100 ° C. When the drying temperature is lower than 60 ° C., it takes too much time for drying and the shrinkage of the foamed molded article is increased.
When the temperature is higher than ℃, the composition of various components contained in the foamed molded article changes, and the flexibility becomes low. In the case of the above hot air dryer, the hot air drying temperature is set to 100 ° C. ± 2.
Pre-stage drying (constant-rate drying) drying at 0 ° C. for 50-80% of the total drying time, and 80 ° C. ± 20 ° C. for a total drying time of 20%
It is preferable to dry in two stages, that is, drying in a later stage (drying at a reduced rate) in which drying is performed for a time period of ５０50%. If the pre-stage drying is performed at a low temperature outside the above range, the drying takes a long time, the shrinkage of the foamed molded article increases, and when the pre-drying is performed at a high temperature, the composition change of various components contained in the foamed molded article occurs, resulting in flexibility. Becomes lower. When the latter drying is performed at a low temperature outside the above range, the drying takes a long time, and when the latter drying is performed at a high temperature, the composition of various components contained in the foamed molded article changes, and the flexibility is lowered. Furthermore, if the hot air drying temperature in the latter drying step is set to a higher temperature than in the former drying step, the drying efficiency is deteriorated only by a constant-temperature drying state in which the product temperature is slightly increased. Although the drying temperature is high in the above, the amount of air mixed is large and the foam is uniformly foamed, so that the gelatin mixed as a binder does not melt out.

The plate-like foamed product of the manufactured product can obtain a good foamed molded product having an absolute dry specific gravity of 0.10 g / cm ^{3 and} a relatively high strength. It is used for various kinds of cushioning materials for packing, car seats, heat insulating materials, sound absorbing materials, and the like.
The laminated foam molded article with paper, cardboard, etc. is widely used for high value-added by imparting a heat retaining and cooling function to the cardboard, and as a curing material for construction and moving. Since the foamed molded article of the present invention is a porous body obtained by mixing paper and the like with a binder,
It has the same function as a conventional foamed chemical resin material as a heat insulating material or a sound absorbing material, but also has a function of adsorbing the odor of an odorous gas. In addition, products made from fibrous substances such as waste paper are made of natural products, so they are easily biodegraded or biodegraded in the natural world, and no harmful substances are generated even when incinerated. Is also excellent.

[0040]

According to the present invention, in producing a plate-like foamed molded article having a wide width and a uniform thickness, an avatar-shaped dent is not generated on the surface, and there is no risk of impairing the appearance as a product. Cavities are hardly generated inside the foamed molded article, and the strength of the foamed molded article can be increased.
By lowering the specific gravity of the foam molded body and improving the yield in the production of cushioning materials with excellent elasticity,
An apparatus and a method for producing a foam molded article that can be mass-produced economically and continuously, and a foam molded article produced by the apparatus and method.

[Brief description of the drawings]

FIG. 1 is an overall configuration diagram of an apparatus for manufacturing a foam molded article according to an embodiment of the present invention.

FIG. 2 is a perspective view of a nozzle portion of a molding machine incorporated in the apparatus for producing a foam molded article of the present invention in a used state.

FIG. 3 is an enlarged view of a main part showing a foaming system body being molded by a molding machine.

FIGS. 4A to 4D are front views of nozzles according to various embodiments.

FIG. 5 (a) is an enlarged bottom view of a nozzle part having an extrusion opening having a continuous triangular shape. FIG. 5B is a perspective view of a sheet-like foam molded article molded by the nozzle of FIG.

FIG. 6A is an enlarged bottom view of a nozzle portion having an extrusion opening having a continuous waveform. FIG. 6B is a perspective view of a sheet-like foam molded article molded by the nozzle of FIG.

FIG. 7 is a perspective view of a sheet-like foam molded body in which a plurality of sheets are laminated.

FIG. 8 is a graph showing the relationship between the foaming specific gravity of the kneaded material and the absolute dry specific gravity.

[Explanation of symbols]

 10: Apparatus for producing a foamed molded body 13: Kneader 16: Foaming machine 17: Molding machine 17 a: Nozzle part 17 b: Extruder 20: Drying machine

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[Procedure amendment]

[Submission date] April 4, 2002 (2002.4.4)

[Procedure amendment 1]

[Document name to be amended] Drawing

[Correction target item name] Fig. 1

[Correction method] Change

[Correction contents]

FIG.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Noboru Maruyama, 2-2-2, Azumori, Izumi-ku, Sendai, Miyagi Prefecture Inside the Miyagi Prefectural Industrial Technology Center (72) Inventor, Kazuhiko Arisumi 2, Akaridori, Izumi-ku, Sendai, Miyagi 2-chome, Miyagi Prefectural Industrial Technology Center (72) Noboru Suzuki, Inventor Suzuki Kogyo Co., Ltd. (72) 5-28, Higashi-cho, Wakabayashi-ku, Sendai-shi, Miyagi Prefecture (72) Inventor Teruaki Sone, Wakabayashi-ku, Sendai-shi, Miyagi Suzuki Kogyo Co., Ltd. (72) 5-28 Higashi Wholesale Town Suzuki Kogyo Co., Ltd. (72) Inventor So Suzuki Kogyo Co., Ltd. (72) Inventor Toshima Exhibition Sendai City, Miyagi Prefecture (72) Inventor Kazumasa Kitada 2-1 Okawacho, Kawasaki-ku, Kawasaki-shi, Kanagawa Prefecture, Mitsui Chemicals Co., Ltd. (72) Inventor Akinori Hazome 2-1 Okawa-cho, Kawasaki-ku, Kawasaki-shi, Kanagawa Prefecture Inside Mitsubishi Chemical Koki Co., Ltd. 3E066 AA01 AA12 BA01 CA01 CA03 CA04 CA08 CB03 DA01 KA08 MA01 4L055 AA11 AG34 AG54 AH21 AH37 AH38 AH50 BA10 BF02 BF03 BF04 BF05 CA09 CJ01 CJ02 CJ04 FA20 FA22 FA30 GA04 GA24 GA50

Claims (30)

[Claims] 1. A kneader for kneading a fibrous substance and an aqueous solution to produce a kneaded product, a foaming machine for foaming the kneaded kneaded product to produce a foam, An apparatus for producing a foam molded article, comprising: a molding machine for producing a molded article by molding into a predetermined shape; and a dryer for drying the molded article. 2. A kneader for kneading a fibrous substance and an aqueous solution to produce a kneaded material, an intermediate tank for temporarily storing the kneaded kneaded material, and a kneaded material supplied from the intermediate tank. A foam molding machine comprising: a foaming machine for producing a foam by foaming; a molding machine for molding the foamed foam into a predetermined shape to produce a molding; and a dryer for drying the molding. Manufacturing equipment. 3. A plurality of kneaders for kneading a fibrous substance and an aqueous solution to produce a kneaded material, and foaming a kneaded material alternately supplied from the plurality of kneaders to produce a foamed material. An apparatus for producing a foam molded article, comprising: a foaming machine; a molding machine for molding the foamed foam into a predetermined shape to produce a molded article; and a dryer for drying the molded article. 4. The molding machine has a nozzle portion for extruding a foam toward an upper surface of a plate-shaped substrate for molding through an extrusion opening, and the plate-shaped substrate and the nozzle portion are relatively positioned. The foam according to any one of claims 1 to 3, wherein the foam moves in a horizontal direction, and the width of the extrusion port of the nozzle portion is at least substantially the same as the width of the plate-like foam molded article. Manufacturing equipment for moldings. 5. The apparatus for producing a foam molded article according to claim 1, wherein a foam supply port side of a nozzle portion of the molding machine is directly connected to the foaming machine. 6. The production apparatus for a foam molded article according to claim 4, wherein the nozzle portion is a divergent nozzle diverging toward an extrusion port having a predetermined thickness. 7. A divergent nozzle having a nozzle portion diverging toward an extrusion opening having a predetermined thickness in a plurality of width directions.
Or the manufacturing apparatus of the foaming molding of Claim 5. 8. The apparatus for producing a foam molded article according to claim 4, wherein the divergent nozzle has an elevation angle of 30 to 85 degrees toward the extrusion opening having a predetermined thickness. 9. The nozzle according to claim 4, wherein a leveling plate for smoothing the surface of the extruded foam molded article and adjusting the thickness in cooperation with the nozzle is attached to the nozzle. 1
An apparatus for producing a foamed molded article according to the above item. 10. The apparatus for producing a foam molded article according to claim 4, wherein the cross-sectional shape of the extrusion opening in plan view or the lower surface of the leveling plate has a continuous triangular shape. 11. The cross-sectional shape of the extrusion opening in plan view or the lower surface of the leveling plate has a corrugated shape.
The apparatus for producing a foamed molded article according to any one of the above. 12. The apparatus for producing a foamed molded product according to claim 4, wherein at least the upper surface of the plate-shaped substrate for molding is processed with a synthetic resin. 13. A foam molded article produced using the production apparatus according to claim 1. Description: 14. A kneading step of kneading a fibrous substance and an aqueous solution to produce a kneaded material, a foaming step of foaming the kneaded material kneaded in the kneading step to produce a foamed product, A foam molding process comprising: a molding step of molding a foamed foam into a predetermined shape to produce a molded article; and a drying step of drying the molded article molded in the molding step at a drying temperature of 60 to 150 ° C. How to make the body. 15. A kneading step of alternately kneading a fibrous substance and an aqueous solution with a plurality of kneaders to produce a kneaded material, and a kneaded material alternately supplied from the plurality of kneaders in the kneading step. A foaming step of producing a foam by foaming the foam, a molding step of molding the foam foamed in the foaming step into a predetermined shape to produce a molded article, and drying the molded article molded in the molding step. A drying step of drying at a temperature of 60 to 150 ° C. 16. The kneading step in which the kneading machine is filled with an aqueous solution in which at least a binder is dissolved, and a fibrous substance is gradually added to the aqueous solution with stirring to knead the mixture. A method for producing a foamed molded article. 17. The method for producing a foam molded article according to claim 14, wherein a foaming specific gravity of the mixture in the foaming step is 0.15 to 0.45 g / cm ³ . 18. A molding machine in a molding step includes a nozzle portion having a size substantially equal to a width of a plate-like foam molded body for extruding a foam toward an upper surface of a plate-like substrate for molding through an extrusion port. Having the plate-shaped base and the nozzle portion relatively moved in a horizontal direction to produce a plate-shaped foamed molded product, and once drying the plate-shaped foamed molded product, further forming the plate-shaped foamed molded product. The laminated foam molded article having an arbitrary thickness is produced by repeating an operation of extruding a foam on the upper surface of the body.
A method for producing a foamed molded product according to claim 17. 19. The method according to claim 14, wherein a fabric is laid on a plate-like base material, and a foam is extruded thereon. 20. The fabric according to claim 19, wherein the fabric is paper or backing paper.
A method for producing a foamed molded article according to the above. 21. The paper according to claim 20, wherein the paper is pre-wet.
A method for producing a foamed molded article according to the above. 22. The method according to claim 20, wherein the fabric is a mount having an uneven shape, and a foam is extruded thereon to a thickness exceeding the height of the convex portion of the uneven shape. 23. The dryer in the drying step is a hot air dryer, and the hot air drying temperature in the drying step is 100 ° C. ± 2.
A first-stage drying (constant-rate drying) process of drying at 0 ° C. for 50 to 80% of the total drying time, and a second-stage drying (decreasing-rate drying) process of drying at 80 ° C. ± 20 ° C. for 20 to 50% of the total drying time The hot air drying temperature of at least the latter drying step is set to a lower temperature than the former drying step.
3. The method for producing a foam molded article according to any one of 2. 24. The drying in the drying step, wherein the volume of the microwave is 0.7 to 2.5 with respect to the weight of the molded body before drying.
The microwave drying is performed under the condition of kW / kg.
A method for producing a foam molded article according to any one of claims 4 to 22. 25. The method for producing a foamed article according to any one of claims 14 to 22, wherein the hot air dryer according to claim 23 and the microwave drying according to claim 24 are used in combination as the drying step. . 26. A foamed product is first extruded from a molding machine onto an endless belt having releasability to form a plate-like molded product, and then the surface of the plate-like molded product is blown with cold air to be dried or dried. The method for producing a foamed molded article according to any one of claims 14 to 25, wherein the method is solidified and further placed on a plate-like substrate in an inverted state. 27. Any one of claims 14 to 26
3. A method for removing foreign matter from a molding machine, comprising: extruding an unfoamed kneaded material into the molding machine described in the above section and flushing out foreign matter remaining in the molding machine. 28. Any one of claims 14 to 17
A foam molded article produced by using the production method described in the above section. 29. Any one of claims 18 to 22.
A foam molded article produced by using the production method described in the above section. 30. Any one of claims 23 to 27.
A foam molded article produced by using the production method described in the above section.