JP2003236938A - Method for manufacturing functional molded product and functional molded product manufactured by using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a functional molded product capable of improving workability, flexibility, air permeability and the like of the molded product by forming the functional molded product of a predetermined shape and improving an efficiency of a functionality applicator as much as possible and to provide the functional molded product using the same. <P>SOLUTION: The method for manufacturing the functional molded product comprises scattering and laminating the functionality applicator 2 and a powder- like or particular hot-melt resin 3 on a film-like or sheet-like base 1 having air permeability, and further coating the film-like or sheet-like coating material 4 having air permeability thereon to form a laminate. The method further comprises the step of filling the functionality applicator 2 and the powder-like or particular hot-melt resin 3 in a mold 5 of a specific shape to form a filler. Then, a steam is passed from one side of these laminate and the filler to the other. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a functional molded article in which a function-imparting agent is formed and fixed in a predetermined shape or a sheet by a specific method, and more specifically, a method for producing a functional material comprising Water vapor is passed through a laminate in which a function-imparting agent and a powdery or granular hot-melt resin are laminated, or a filler having a specific shape consisting of the function-imparting agent and a powdery or granular hot-melt resin. Then, by melting the hot-melt resin by heat of steam to develop adhesiveness,
Forming the functionalizing agent into a sheet shape or a predetermined shape,
Predetermined (optional) regarding the manufacturing method of the functional molding to be fixed
Functionality that obtains a functional molded body that is shaped and porous, and that improves the processability, flexibility, and air permeability of the functional molded body, and that also improves the function and efficiency of the functionalizing agent. The present invention relates to a method for manufacturing a molded product and a functional molded product manufactured using this method.

[0002]

2. Description of the Related Art Generally, in living spaces such as indoors,
Dust and dust, carbon monoxide and water vapor generated from cooking appliances, heating appliances, etc., sick house causative substances such as formaldehyde and toluene generated from residential building materials, and living odors such as ammonia odor from people and pets are constantly generated. ,Existing.

In a conventional Japanese-style house, since it is well ventilated and uses building materials such as earthen walls, tatami mats, shoji, etc., the building itself using this building material contains the above-mentioned moisture and substances to some extent. It played a role of adsorbing and controlling the humidity.

However, in Japan in recent years, many Western style houses have become widespread, and earthen walls, tatami mats, etc. have been replaced by panel boards, flooring, etc., and the building itself has become highly airtight. It is said that the function of adsorbing water and other components of the product and the function of absorbing moisture are deteriorated, and as a result, mites and molds are generated, and so-called living odors and allergies are caused.

Therefore, recently, it has become indispensable to install an air purifier, an air conditioner or the like in the room, or to use a deodorant or an adsorbent.

By the way, in these air cleaners and air conditioners, as an adsorbing / deodorizing element, an adsorbent such as activated carbon is carried on a breathable cloth base material such as non-woven fabric, woven fabric or net. Adsorption sheets are often used, and for deodorants, etc., it is common to form a breathable cloth base material such as nonwoven fabric or woven cloth into a bag shape and enclose an adsorbent such as activated carbon. It is used.

Generally, as a method of supporting an adsorbent such as activated carbon on a breathable cloth base material such as a non-woven fabric, a woven cloth or a net, an adhesive is applied to the cloth base material and the activated carbon is then applied. A method of spraying an adsorbent such as

However, according to this method, the air holes in the cloth base material are blocked by the adhesive, and not only the flexibility and air permeability of the cloth base material are significantly impaired, but also the adsorbent such as activated carbon is buried in the adhesive. Therefore, there is a problem that it becomes difficult to obtain a desired adsorption effect.

Further, in the case of a deodorant or the like in which a breathable cloth base material such as a non-woven fabric or a woven fabric is formed into a bag and an adsorbent such as activated carbon is enclosed, the enclosed adsorbent may be biased or adsorbed. There was a problem that the material leaked.

In view of these problems, Japanese Patent Laid-Open No. 5-131
In JP-A-136, since it is used for a deodorizing element such as an air cleaner or an air conditioner, the activated carbon particles are evenly distributed to the inside of a tissue such as a nonwoven fabric, and the activated carbon particles are retained while maintaining the sheet carrying stability. A thermoplastic synthetic fiber having a core-sheath structure is used for the purpose of providing a method for producing an activated carbon adhesive sheet in which fibers inside a tissue are adhered, and the melting point of the sheath is at least 10 ° C from the core.
A sheet of knitted fabric, woven fabric, non-woven fabric, web, or the like, which is made of a low polymer, is sprayed with activated carbon particles, or after being blown with hot air containing activated carbon particles, further blown with hot air and sucked from the back side to obtain the sheet. Disclosed is a technical means characterized by adhering activated carbon to the.

Further, in Japanese Patent Laid-Open No. 2001-18312, breathability is provided for the purpose of providing a sheet that ensures retention of carbon particles and has a sufficient humidity control ability in any form. The Bincho charcoal particles are bonded between the non-woven fabric and the covering material by an adhesive agent, and the Binchocharcoal particles are bonded to each other and the Binchocharcoal particles and the non-woven cloth and the covering material are formed into a continuous sheet having a substantially uniform thickness. The technical means to be disclosed is disclosed.

[0012]

However, in the method for producing an activated carbon adhesive sheet described in JP-A-5-131136, a thermoplastic synthetic fiber having a core-sheath type structure is used, and the melting point of the sheath is at least that of the core. Since it is premised that a special sheet such as a polymer sheet having a temperature lower than 10 ° C. is used, there is a problem in that the cost becomes high. Further, after the activated carbon particles are sprinkled on the sheet, hot air is further added. By spraying and sucking from the back side, activated carbon particles are carried on the fiber mesh of the sheet.
With the technical means such as adhesion, there is a limit to the amount of activated carbon that can be supported, and there is a problem that the mesh of the fiber network is clogged by the activated carbon particles and the adhesive, which impairs air permeability and flexibility. .

Further, in this method, since the amount of heat of the hot air is low, it is necessary to raise the temperature to a high temperature or to pass the hot air for a long time. As a result, the base material and the covering material are thermally deteriorated by heat or oxygen in the air. Since it deteriorates, there is a problem in terms of durability.

On the other hand, the humidity control sheet described in Japanese Patent Laid-Open No. 2001-18312 does not require a special sheet because it has a laminated structure in which Bincho charcoal particles are sandwiched between a nonwoven fabric and a covering material, and There is an advantage in that the amount of activated carbon sandwiched can be adjusted appropriately.

However, in the manufacturing method,
Bincho charcoal particles are mixed with a heat-soluble powder adhesive and stirred, and the mixture is evenly laid on a continuously transferred non-woven sheet and pressed by a heating roller to dissolve the adhesive. Since the technical means of adhering the Bincho charcoal particles to each other and the non-woven fabric and the covering material to form a continuous sheet having a substantially uniform thickness is adopted, the Bincho charcoal particles are buried in the melted adhesive. Not only is the desired adsorption effect not obtained, but the flexibility of the sheet is significantly impaired by the pressure applied by the heating roller, and as in the case of JP-A-5-131136, the fiber network of the nonwoven sheet is There is a problem that clogging occurs due to melting of Bincho charcoal particles and heat-soluble powder adhesive.

Further, in this manufacturing method, the laminate in which the Bincho charcoal particles are sandwiched between the non-woven fabric and the covering material is heated from the surface thereof by the heating roller. In this case, the heat of the heating roller is applied to the surface of the laminate. From the inside to the inside, it takes time to melt the heat-meltable powder adhesive with this heat and develop the adhesiveness, resulting in low productivity and thermal deterioration and deterioration of the non-woven fabric and covering material. There is a problem in terms of durability.

As a result of intensive studies to solve the above-mentioned problems, the present inventor first found that a functional agent and a powdery or granular hot melt were formed on a film-like or sheet-like substrate having air permeability. A resin or a resin, or a mixture of a functionalizing agent and powdery or granular hot-melt resin is sprayed and laminated, and then a film-like or sheet-like covering material having air permeability is formed thereon. A laminate is formed by covering, and then steam is passed in the thickness direction of the laminate to melt the hot-melt resin by heat of steam to develop adhesiveness and cover the base material. By adopting a manufacturing method such as fixing the function-imparting agent between the material and the material, it has been found that it is possible to manufacture an extremely excellent sheet-shaped functional molded product that can solve the technical problems. .

That is, the present inventor has spread the function-imparting agent and the powder-like or granular hot-melt resin on the air-permeable film-like or sheet-like base material, stacking it, or imparting the functionality. A technical means of forming a laminate by spraying and laminating a mixture of an agent and powdery or granular hot-melt resin, and further covering the mixture with a breathable film-like or sheet-like covering material. It has been found that by adopting the above, it is possible to prevent the leakage of the function-imparting agent and to appropriately adjust the amount of the function-imparting agent to be sandwiched.

Further, the inventor of the present invention melts the hot melt resin by the heat of water vapor by causing water vapor to pass through in the thickness direction of the laminate so that the hot melt resin exhibits adhesiveness, thereby forming a base material and a coating material. By fixing the functionalizing agent in between, by adopting a technical means such as, it is possible to fix the functionalizing agent in a short time without impairing the air permeability and flexibility,
They also found that the activity of the functionality-imparting agent can be maintained.

The production method based on the above knowledge can produce only a sheet-shaped functional molded article,
In order to develop the above-mentioned findings, the present inventor has conducted further diligent studies, and as a result, filled the mold having a specific shape with the functionalizing agent and powdery or granular hot melt resin, and then from one of the filled materials. By passing steam on the other side, the hot melt resin is melted by the heat of steam to develop adhesiveness, and the functionalizing agent is formed and fixed in a predetermined shape, thereby solving the technical problem. In addition, it has been found that a functional molded product having an arbitrary shape can be manufactured.

The present invention has been completed based on these findings, and it is possible to improve the processability, flexibility and air permeability of the functional molded article and to impair the activity of the functionalizing agent. Without, for the purpose of providing a method for producing a novel functional molded article that can also extremely improve the efficiency of the functionalizing agent, further, building materials, deodorants, desiccants, bactericides, antifungal agents, It is also an object to provide a functional molded product that can be applied to a health tool, a small animal repellent, a care sheet, and the like.

[0022]

In order to achieve the above object, in the method for producing a functional molded article of the present invention (hereinafter referred to as the first method of the present invention), a gas-like film or sheet having air permeability is provided. On the base material of (1), a functionalizing agent and a powdery or granular hot melt resin are laminated, and a laminate is formed by further covering with a film-like or sheet-like covering material having air permeability. , Then, by passing water vapor in the thickness direction of this laminate, the hot melt resin is melted by the heat of water vapor to develop adhesiveness,
The technical means of fixing the functionality-imparting agent between the base material and the coating material is adopted.

In order to achieve the above-mentioned object, in the method for producing a functional molded article of the present invention (hereinafter referred to as the second method of the present invention), a mold having a specific shape and a functional agent and powder are used. Granular hot-melt resin is filled, and steam is passed from one side of the filling to the other, thereby melting the hot-melt resin by heat of steam to develop adhesiveness, and the function-imparting agent. It adopts the technical means of forming and fixing the above into a predetermined shape.

That is, in the first method of the present invention and the second method of the present invention, the hot-melt resin is melted by the heat of steam,
In common with the point of exhibiting adhesiveness, the first method of the invention is such that a functionalizing agent and a powder or granular hot melt resin are provided between a film-like or sheet-like material having air permeability and a covering material. In contrast to the method for producing a sheet-shaped functional molded article by treating a “laminate” in which the above are laminated with steam, the second method of the present invention is a method of the second aspect of the present invention, in which a mold having a specific shape is mixed with a functionalizing agent and powder. The difference is that it is a method of producing a functional molded product having a predetermined (arbitrary) shape by treating a "filler" filled with a granular or granular hot melt resin with steam.

In producing the "laminate" in the first method of the present invention or the "filling material" in the second method of the present invention, the function-imparting agent and the powdery or granular hot melt resin are separately prepared. It is laminated or filled, or a mixture of the functionalizing agent and powdery or granular hot melt resin is laminated or filled. Hereinafter, the first method and the second method of the present invention will be described in more detail in order.

The breathable film-like or sheet-like base material and covering material used in the first method of the present invention are not particularly limited as long as they are film-like or sheet-like cloth bodies having good breathability. Moreover, it is not necessary to use a special fiber as the fiber constituting the cloth body.

That is, in the first method of the present invention, it is not necessary to use a material having a special property as the base material or the coating material as long as it has air permeability, so that the material cost and the final product are In consideration of the thickness, the basis weight, the air permeability, the strength, etc., the most suitable base material or cloth material as a coating material can be appropriately selected.

Generally, in the first method of the present invention, the cloth used as the base material and the covering material may be a cloth made of natural fibers and / or artificial fibers. As the cloth body made of and / or artificial fibers, cloth, towel cloth, blanket, quilt, knit, non-woven cloth and woven cloth can be generally mentioned.

Examples of the natural fiber include cotton,
Plant fiber such as kapok, flax, ramie, cannabis, jute, spiro, manila, sisal, coyer fiber,
Examples of animal fibers include domestic silk, tulip silk, wool (sheep), cashmere hair, camel hair, alpaca hair, mohair, and rabbit hair.

Examples of the artificial fibers include recycled fibers such as artificial silk thread, suf, viscose, and bemberg, polyamide fibers (such as nylon), polyester fibers (such as tetron, terylene, and decron), and polyacrylic fibers. Fiber (Auron, Exlan, Bonnell, Casimirone, Kanecaron, etc.), Polyvinyl / alcohol fiber (Vinylon), Polyalkylene paraoxybenzoate fiber (benzoate), Polyurethane fiber (Polyurethane) [Spantex], Polyvinylidene chloride fiber (Vinylidene), polyvinyl chloride fiber (polyvinyl chloride), polyacrylonitrile fiber, polyethylene fiber (polyethylene), polypropylene fiber (polypropylene), polyclar, polypropylene (pyrene), etc. Wei, or semi-synthetic fibers such as that manufactured the with natural substances and synthetic substances copolymerized with such as acetic artificial fibers.

In the first method of the present invention, a laminate of at least one selected from these cloths may be used as the base material or the covering material.

In the first method of the present invention, the functionalizing agent and the powdery or granular hot melt resin are laminated on the base material selected from these cloths, and further thereon. By forming a laminate by covering with a film-like or sheet-like covering material having breathability from the above, by employing a technical means such as preventing the leakage of the functionality-imparting agent, and further The amount can be adjusted appropriately.

In the first method of the present invention, the function-imparting agent and the powdery or granular hot melt resin may be laminated "individually" on the substrate, or the function-imparting agent and the powder may be laminated. A “mixture” with a hot or melt hot or granular resin may be laminated.

More specifically, in the case of "individually" laminating, a functionalizing agent and a powdery or granular hot melt resin are laminated in this order on the base material, and the coating is further applied thereon. A laminated body may be formed by covering with a material, or if desired, a plurality of laminated bodies may be laminated. Further, the functionality-imparting agent and powdery or granular hot-melt resin on the base material. It is also possible to form a laminated body by alternately laminating and repeating the above a plurality of times and then covering the laminated body with the covering material, or, if desired, a plurality of laminated bodies. Is
They are fixed to each other by the method described later.

When the "mixture" is laminated, a mixture of the functionalizing agent and powdery or granular hot melt resin is laminated on the base material, and the coating material is further formed thereon. It is also possible to form a laminated body by covering with, or to laminate a plurality of laminated bodies if desired, and these laminated bodies are fixed to each other by a method described later.

That is, in the first method of the present invention, when the function-imparting agent and the powdery or granular hot-melt resin are sprayed and laminated on the base material, the function-imparting agent is laminated on the base material, Further, a powdery or granular hot melt resin is laminated thereon, or the functionality-imparting agent and the powdery or granular hot melt resin are alternately mixed and laminated a plurality of times without mixing. Alternatively, the mixture of the functionalizing agent and the powdery or granular hot-melt resin may be sprinkled and laminated on the base material. Which method should be adopted depends on the functionalization. It is appropriately determined depending on the physical properties and types of the agent and the powdery or granular hot-melt resin, the application, and the like.

In the first method of the present invention, the steam is allowed to pass through the laminated body obtained by the above-described method in the thickness direction, so that the steam is brought into direct contact with the powdery or granular hot-melt resin. The most characteristic feature is that the heat-melting resin melts the hot-melt resin to develop adhesiveness, thereby fixing the functionality-imparting agent between the base material and the coating material. Have.

By the way, in the first method of the present invention, water vapor is passed in the thickness direction of the laminate as described above. For example, in this laminate, water vapor is passed from the base material side to the coating material side. In such a case, the flexibility of the coating material may be slightly lowered. In such a case, the flexibility of the coating material can be restored by passing water vapor from the coating material side to the base material side again.

In the first method of the present invention, the reason why the function-imparting agent is fixed between the base material and the coating material by allowing water vapor to pass through in the thickness direction of the above-mentioned laminated body is, first, that the water vapor is hot air. The amount of heat is higher than that of, and by directly contacting with powdery or granular hot melt resin, it is possible to melt the hot melt resin in a very short time even at a relatively low temperature and develop adhesiveness. , The base material and the covering material are not deteriorated and deteriorated, that is, oxygen in the air may oxidize and deteriorate with hot air, but when steam is used, such an adverse effect is eliminated. The function-imparting agent used in the first method of the invention includes a substance which is easily oxidized or a substance which is easily decomposed by heat, and a substance which loses its activity. Also used It became a performance.

Further, in the method of the present invention, not only hot air but water vapor is passed through in the thickness direction of the laminate,
By directly contacting with powdery or granular hot-melt resin, the hot-melt resin can be melted in a very short time even at a relatively low temperature to exhibit adhesiveness. By passing through, the clogging of the fiber network in the base material and the covering material does not occur, and since pressing by a heating roller is not required, the flexibility of the final product is improved.

Furthermore, when steam is used in the first method of the present invention, the temperature of the steam is relatively easy to control, and the steam can pass through the base material and the covering material, so that the effect of directly conducting heat is very high. However, the time required to develop the adhesiveness to the powdery or granular hot-melt resin becomes a very short time (several seconds to several tens of seconds), and also in this point, the deterioration of the functionality-imparting agent is almost caused. In addition, the base material and the covering material are not deteriorated or thermally deteriorated.

By the way, in the first method of the present invention, to allow water vapor to pass through in the thickness direction of the laminate means that the base of the laminate has a constitution of "base material / functionality-imparting agent + hot-melt resin / coating material". It means passing water vapor from the material side toward the coating material side, or passing water vapor from the coating material side toward the substrate side.

The water vapor used here means water vapor under normal pressure. Therefore, although its temperature varies depending on the melting point of the powdery or granular hot-melt resin used, it is generally under normal pressure. It is not particularly limited as long as it is water vapor of 100 ° C. or higher, but in the method of the present invention, in order to cause the hot melt resin to melt and develop adhesiveness in a short time, a temperature range of 105 to 180 ° C., particularly, 1
It is preferable to use steam in the range of 10 to 150 ° C. In this case, when the temperature of the steam is as high as 180 ° C., the specificity-imparting agent is a specific case like activated carbon, but rather when the function-imparting agent is steam, the activation of the activated carbon is promoted, and in a very short time, Since the hot-melt resin can be melted and the adhesiveness can be exhibited, the base material and the covering material are not deteriorated and thermally deteriorated.

By the way, in the first method of the present invention, in passing the water vapor as described above, the water vapor may be passed through the laminated body in the thickness direction thereof and may be sucked from the opposite surface. With such a structure, the steam reliably and uniformly contacts the hot-melt resin, and a sheet-like functional molded product with stable quality can be obtained. Further, it is not always necessary to pass the water vapor perpendicularly to the laminated body, and the water vapor may be passed obliquely, and the point is that the laminated bodies are joined to each other by the passage of the water vapor.

The function-imparting agent preferably used in the first method of the present invention is one or a mixture of two or more agents, and has a deodorizing action, a deodorizing action, a water absorption / humidity adjusting action, and an electromagnetic wave. Absorption, sterilization, antifungal action, small animal repellent action, insecticidal action, deoxygenation action, aroma action, negative ion generation action or far-infrared radiation action, etc. In the first method of the invention, a known substance can be used as appropriate as long as it does not lose its activity.

In the first method of the present invention, these functionalizing agents can be used in any form such as liquid, powder, particles, microcapsules, etc., and further, if necessary. You may add additives, such as a surfactant.

As an example of this specific functionality-imparting agent,
First, as a functionalizing agent that adsorbs harmful substances that cause sick house such as formaldehyde and alkylbenzene and substances that cause living odors in the room, and has a deodorizing action, a deodorizing action, or a water absorption / humidity adjusting action. It is not particularly limited as long as it is a substance that adsorbs and holds these substances, and specifically, for example, oxides, hydroxides or chlorides of alkaline earth metals or transition metals such as calcium oxide and magnesium oxide. Examples thereof include silica gel, zeolite, perlite, permiculite, alumina, activated carbon, and activated clay. At least one selected from these substances can be used in the first method of the present invention. .

Further, if necessary, a substance such as phenol, potassium permanganate, or a plant extract which has a chemical adsorption action or decomposes a living odor to exhibit a deodorizing effect may be appropriately added. .

In the first method of the present invention, as the function-imparting agent having an electromagnetic wave absorbing action, those which suitably absorb electromagnetic waves such as black charcoal, those which convert electromagnetic waves such as metal fibers and carbon fibers into heat energy, etc. Can be mentioned.

As the function-imparting agent having a bactericidal action, a mildew-proofing action, a repellent action for small animals, and an insecticidal action,
Fungicides, fungicides, small animal repellents, insecticides and the like can be used, and are not particularly limited, and specifically, for example, orange peel oil, lemon oil, bergamot oil,
Citrus essential oils such as boiled oil, pine needle oil, peppermint oil, turpentine oil and camphor oil, terpenes such as limonene,
Mustard, wasabi, etc. and pungent components contained therein (capsaicin, denatonium benzoate, etc.), and others, wood vinegar oil, hinokitiol, natural rubber, kerosene, caprin aldehyde, capryl aldehyde, silatol, acetic acid, tannin or plant extracted oil, etc. Therefore, in the method of the present invention, at least one selected from these substances can be used.

In the first method of the present invention, examples of the function-imparting agent having a deoxidizing action include metal powder represented by iron powder.

In the first method of the present invention, known aromatic agents can be appropriately selected and used as the functionalizing agent having an aromatic effect.

In the first method of the present invention, as the function-imparting agent having a function of generating negative ions, negative ions are generated by ionization by air discharge, or by ionization of air in the air range of radiation by natural radiation. It is possible to cite a negative ion generating action for generating a negative ion, and preferred examples of the negative ion generating action for suitably generating a negative ion by such an action include tourmaline, rare earth ore, charcoal or coconut husk charcoal. be able to.

The function-imparting agent having a far-infrared radiation function is not particularly limited as long as it has a function of suitably radiating a radio wave having a wavelength range near the far-infrared region. It is preferable to use a non-metal inorganic solid (far-infrared radiation ceramics) that emits, and specifically, at least one selected from metal oxides, carbides, nitrides and carbonates can be appropriately selected and used. it can.

The metal in the far-infrared radiation ceramic is not particularly limited, but for example, Al, Be, V, Fe, Y, Co, Cu, Ni, S.
i, Sn, Ti, Cr, Ce, Zr, Ca, Ta and N
The metal selected from b etc. can be mentioned.

The hot melt resin used in the first method of the present invention is not particularly limited as long as it is powdery or granular and exhibits adhesiveness when treated with steam, Specifically, for example, polyethylene, polypropylene, ethylene-vinyl acetate copolymer,
At least one selected from methacrylic resins, polystyrene and copolymers, polyisobutylene, polyamide resins, polyester resins and the like can be mentioned.

Then, in the first method of the present invention, the ratio of each component when the function-imparting agent and the powdery or granular hot melt resin are sprayed and laminated on the substrate is selected. Alternatively, it is not particularly limited and can be appropriately determined according to the type and air permeability of the coating material, the type of the selected function-imparting agent or the type of the hot-melt resin, but generally, the function-imparting is provided. In the range of 30 to 150 parts by weight of hot-melt resin, particularly 50
It is preferably in the range of up to 100 parts by weight.

When the amount of the hot-melt resin is less than 30 parts by weight with respect to 100 parts by weight of the function-imparting agent, the amount of the function-imparting agent is too small to fix the function-imparting agent. When a cloth body is used as a base material or a covering material, leakage of the functionalizing agent occurs, which is not preferable.
If the amount exceeds 50 parts by weight, not only is the amount too large and wasteful, but also the relative proportion of the function-imparting agent decreases, and the desired effect cannot be obtained.

In the first method of the present invention, the final amount of the functional molded product is the amount of the functional additive and the powdery or granular hot-melt resin dispersed and laminated on the substrate. It is appropriately determined depending on the performance required for the purpose and the application, and is not particularly limited, but generally, it is preferably in the range of 50 to 1500 g / m ² , and this lamination amount is based on It can be easily adjusted by the feeding speed of the material, the vertical gap of the coater, the falling speed, and the like.

Next, the second method of the present invention will be described in detail.

As described above, in the second method of the present invention, the mold having a specific shape is filled with the function-imparting agent and the powdery or granular hot-melt resin, and steam is passed from one of the fillings to the other. By so doing, the hot melt resin is melted by the heat of water vapor to develop adhesiveness, and the functionalizing agent is formed and fixed in a predetermined shape, which is a technical means.

Here, the "mold of a specific shape" refers to a container having an arbitrary shape which can be filled with the functionalizing agent and the powdery or granular hot melt resin, and the shape thereof is not particularly limited. Although not required, at least an inlet for sending in steam and an outlet for outflow of steam must be provided.

The inlet or outlet should be constructed so that these components will not easily spill when the functionality-imparting agent and powdery or granular hot melt resin are filled. Specifically, for example, the inlet and the outlet may be installed above the mold, or the inlet or the outlet may be closed with a breathable material such as a cloth, a net, or a wire net.

The material forming the mold of this particular shape is not particularly limited as long as it does not easily melt or break when treated with steam, and generally, wood or Natural materials such as bamboo, metal materials such as iron, heat-resistant polymer materials, pottery and ceramic materials, etc. can be preferably used.

Further, also in the second method of the present invention, as described in the first method of the present invention, the function-imparting agent and the powdery or granular hot-melt resin are laminated "individually" on the mold of a specific shape. It may be filled, or may be filled with a "mixture" of the functionality-imparting agent and the powdery or granular hot melt resin, and detailed description thereof is omitted to avoid repetition.

In the second method of the present invention, steam is passed from one side (inlet) to the other side (outlet) of the packing obtained by the above-mentioned method, whereby the steam and powdery or granular hot melt are mixed. Direct contact with the system resin,
The hot melt type resin is melted by the heat of the steam to develop adhesiveness, and thereby the function-imparting agent is formed and fixed in a predetermined shape. .

In this case, the predetermined shape is not particularly limited, but specifically, for example, a rectangular parallelepiped shape,
Examples thereof include a cubic shape, a spindle shape, a spherical shape, a disc shape, a circular / polygonal column shape, a tubular shape, a small animal shape, a tile shape or a block shape.

In the second method of the present invention, the above-mentioned filler is treated with steam to form the function-imparting agent into a predetermined shape.
The reason for fixing, the steam used and the method of passing steam, etc. are the same as those described in the first method of the present invention, and are omitted here to avoid repetition.

Further, as the function-imparting agent and the hot-melt resin which are preferably used in the second method of the present invention, the same ones as described in the first method of the present invention can be used, and Regarding the blending ratio of the hot-melt resin and the functionality-imparting agent, the same ones as those described in the first method of the present invention can be used, and therefore the description thereof is omitted here to avoid redundant description.

The functional molded article according to the present invention is manufactured by using the first method of the present invention or the second method of the present invention (hereinafter referred to as the present invention method) in order to achieve the above object. It is a molded product and is preferably used as an adsorbing element for air cleaners, air conditioners, deodorizers, etc., and various products such as building materials and drying materials depending on the type of the functionalizing agent used. It can be used as an agent, a bactericide, a health tool, an antifungal agent, a care sheet, a deodorant or a repellent for small animals.

That is, in the functional molded article produced by using the method of the present invention, functions corresponding to various functionalizing agents are exhibited.
Floor materials, shoji paper, building materials such as wallpaper or bran paper, water absorption / humidity regulators, desiccants, bactericides, fungicides, deodorants, deodorants,
Examples include small animal repellent action, insoles, footwear, health equipment, and care sheets.

[0072]

EXAMPLES The first method of the present invention, the second method of the present invention and the functional moldings produced by these methods will be explained in detail with reference to the drawings, but the present invention is limited to these examples. It is not something that will be done.

First Method of the Present Invention As shown in FIG. 1, in the first method of the present invention, first,
The functionalizing agent 2 and the powdery or granular hot-melt resin 3 are sprinkled and laminated on a breathable film-like or sheet-like base material 1, and further, a breathable film-like substance is formed thereon. Or, a laminated body is formed by covering with a sheet-shaped covering material 4.

Here, when the function-imparting agent 2 and the powdery or granular hot-melt resin 3 are sprayed and laminated on the base material 1, the function-imparting agent 2 and the powdery or granular hot-melt type resin 3 are dispersed. The resin 3 and the resin 3 may be separately sprayed or laminated, or
A mixture of the functionality-imparting agent 2 and the powdery or granular hot-melt resin 3 may be sprinkled and laminated.

As the base material 1 and the covering material 4, for example, a cloth body made of natural fibers and / or artificial fibers can be cited. As the cloth body made of the natural fibers and / or artificial fibers, a general cloth is used. Examples of the material include cloth, towel cloth, blanket, quilt, knitting, non-woven cloth and woven cloth.

Further, as the function-imparting agent 2, one kind or a mixture of two or more kinds of agents is used, and it has a deodorizing action, a deodorizing action, an electromagnetic wave absorbing action, a water absorbing / humidifying action, a deoxidizing action, Small animal repellent action, insecticidal action, bactericidal action, antifungal action,
It refers to those exhibiting various actions (functions) such as aroma action, far-infrared radiation action, and negative ion generation action. In the method of the present invention, these functionalizing agents 2
Can be used in any form such as liquid, powder, particles, microcapsules and the like, and if necessary, an additive such as a surfactant may be added.

Further, the hot-melt resin 3 is not particularly limited as long as it exhibits adhesiveness when treated with steam S, and specific examples thereof include polyethylene, polypropylene and ethylene. At least one selected from vinyl acetate copolymer, methacrylic resin, polystyrene and copolymer, polyisobutylene, polyamide resin or polyester resin can be mentioned.

In the first method of the present invention, as shown in FIG.
As described above, by passing the water vapor S in the thickness direction of the laminate, for example, from the coating material 4 toward the substrate 1, the heat of the water vapor S melts the hot-melt resin 3 and the adhesiveness is improved. And the function-imparting agent 2 is fixed between the base material 1 and the coating material 4.

Second Method of the Present Invention As shown in FIGS. 3 and 4, in the second method of the present invention, first, a mold 5 having a specific shape is provided with a functionalizing agent 2 and a powdery or granular hot melt resin. And 3 to form a filling M.

When the mold 5 having a specific shape is filled with the function-imparting agent 2 and the powdery or granular hot-melt resin 3, the function-imparting agent 2 and the powdery or granular hot-melt resin 3 are filled. 3 may be separately laminated and filled, but in this embodiment, a mixture of the functionalizing agent 2 and the powdery or granular hot melt resin 3 is filled.

As the mold 5 having a specific shape in this embodiment, a cylindrical shape is used, but the shape is not particularly limited.

The material constituting the mold 5 having the specific shape is not particularly limited as long as it does not easily melt or break when treated with the steam S.
Generally, natural materials such as wood and bamboo, metallic materials such as iron, heat-resistant polymer materials, pottery and ceramic materials, etc. can be preferably used.

As shown in FIGS. 5 and 6, the mold 5 having a specific shape shown in FIG. 3 has water vapor S over the entire upper surface of the cylindrical mold 5.
A steam inflow part 6 for sending in water and a steam outflow part 7 for outflowing the water vapor S are provided on the entire bottom surface of the cylindrical mold, and the water vapor S can be sucked from the water vapor outflow part 7. There is.

In the present embodiment, when the functionality-imparting agent 2 and the powdery or granular hot-melt resin 3 are filled, these components are prevented from spilling over the entire steam outflow portion 7. A cloth body 8 is provided.

Then, in the second method of the present invention, as shown in FIG.
And as shown in FIG. 6, the water vapor S from the water vapor inflow portion 6 toward the water vapor outflow portion 7 in the filling material M filled in the mold 5.
To melt the hot-melt resin 3 by the heat of the water vapor S to develop adhesiveness, and form and fix the function-imparting agent 2 into an arbitrary shape (in this case, a cylindrical shape). Of. In this case, the water vapor S in the processing chamber
A pipe-shaped water vapor inflow portion 6 for inflowing the water vapor and a pipe-shaped water vapor outflow portion 7 for outflowing the inflowing water vapor S are respectively provided on the side surfaces of the processing chamber so that the water vapor S can be sucked from the water vapor outflow portion 7. It is configured.

The functional molded article produced by the method 1 or 2 of the present invention is preferably used as an adsorbing element for an air cleaner, an air conditioner, a deodorizer, or the like, and the function used. It can be applied to various products depending on the type of the sex imparting agent.

Example 1 (1) Preparation of Laminate A rayon non-woven fabric (30 cm × 30 cm, basis weight 20 g / m ² ) was used as a base material, activated carbon powder (20 g) was used as a function-imparting agent, and a hot melt resin was used. A mixture of ethylene-vinyl acetate copolymer powder (15 g) was sprayed and laminated, and a rayon non-woven fabric (30 cm × 30 cm, basis weight 20 g / m ² ) as a covering material was further coated thereon to form a laminate. . (2) Preparation of functional molded body Then, by passing steam at 140 ° C. in the thickness direction of the laminate of (1) above, the heat of the steam melts the ethylene-vinyl acetate copolymer powder, Adhesiveness was developed and activated carbon was fixed to obtain a sheet-shaped functional molded product (deodorant) of the present invention. The time required to develop the adhesiveness of the hot melt resin (ethylene-vinyl acetate copolymer) by passing water vapor is 2
It was 0 seconds.

Example 2 (3) Preparation of Filler Cylindrical pottery as a mold having a specific shape (outer diameter 6.5 cm, inner diameter 5 cm, height 5 cm, open top and bottom)
Non-woven fabric made of rayon (30 cm × 30 cm,
A grammage of 20 g / m ² ) was used, and a mixture of activated carbon powder as a function-imparting agent and ethylene-vinyl acetate copolymer powder as a hot-melt resin (mixture of 4: 3) was used in this mold.
To form a packing. (4) Preparation of Functional Molded Product Then, steam of 140 ° C. is passed from the upper surface to the bottom surface of the filling material of (2) to heat the ethylene-vinyl acetate copolymer powder with the heat of the steam. Melting,
By exhibiting adhesiveness, fixing the activated carbon, and removing from the mold, the cylindrical functional molded body of the present invention (deodorant)
Got The time required for the hot melt resin to exhibit adhesiveness by passing water vapor was 20 seconds.

Comparative Example 1 The hot melt resin (ethylene-vinyl acetate copolymer powder) was melted by the heat of the hot air by passing hot air of 140 ° C. in the thickness direction of the laminate of (1). Then, the adhesiveness was developed, and a sheet-shaped body supported by activated carbon was obtained. The time required to melt the ethylene-vinyl acetate copolymer powder and develop the adhesiveness by passing hot air was 180 seconds.

Comparative Example 2 The laminate of (1) above was placed in a constant temperature bath at 140 ° C., and a constant temperature was reached when the surface temperature of the mixture of the ethylene-vinyl acetate copolymer powder and activated carbon in the laminate reached 140 ° C. The sheet was taken out from the tank and then pressed with a roller to obtain a sheet-shaped body carrying activated carbon. In the thermostat, the surface temperature of the mixture of the ethylene-vinyl acetate copolymer powder and the activated carbon in the laminate reached 140 ° C, and the ethylene-vinyl acetate copolymer powder was melted until the adhesive property was developed. It took 5 to 6 minutes to fix the functionalizing agent (activated carbon).

The physical properties (breathability, hygroscopicity, flexibility) of the functional molded body obtained in Example 1 and the sheet-like body carrying the activated carbon obtained in Comparative Examples 1 and 2 were measured.
Table 1 shows the results of the comparison.

In the evaluation of each physical property, regarding the air permeability, the functional molded body obtained in Example 1 and Comparative Example 1 were used.
The air permeability of the activated carbon-supported sheet-like body obtained in 2 was measured with a Gurley measuring device, and the sheet-like bodies of Comparative Examples 1 and 2 were obtained when the air permeability of the functional molded body of the example was 100. It is a numerical representation of the relative breathability of the body.

Regarding the hygroscopicity, the thermostatic chamber (temperature 35
In a thermostat at 90 ° C. and a relative humidity of 90%, the functional molded body obtained in Example 1 and the sheet-like body carrying the activated carbon obtained in Comparative Examples 1 and 2 were allowed to stand for 1 hour to carry out. 3 is a numerical representation of the relative weight change of each sheet-shaped body of Comparative Examples 1 and 2 when the weight change of the functional molded article of the example is 100.

Further, regarding the flexibility, the tester actually touched the functional molded body obtained in Example 1 and the sheet-like body carrying the activated carbon obtained in Comparative Examples 1 and 2, and the tactile sensation was obtained. Is evaluated.

[0095]

[Table 1]

From the test results of Example 1 and Comparative Examples 1 and 2, it is possible to manufacture the functional molded article of the present invention in an extremely short time as compared with the sheet-shaped article of Comparative Examples 1 and 2. It was also confirmed that it is possible to prevent the occurrence of clogging and the like due to thermal deterioration of the base material and the covering material, and to prevent the deterioration of breathability and flexibility.

Further, the functional molded body obtained in Example 1 and the sheet-like body obtained in Comparative Examples 1 and 2 were 5 cm in length and 5 c in width.
It was cut into m squares and laid in a 15 liter desiccator.

Next, the air in these desiccators was evacuated by a vacuum device to make a vacuum, and then the desiccators were filled with air containing 50 ppm of ammonia, respectively, and after 10 minutes, 30 minutes and 1 hour. After 5 hours and 1
The change in the concentration of ammonia after 0 hours was measured with a Kitagawa type detector tube. The results are shown in Table 2.

[0099]

[Table 2]

From the results shown in Table 2, it was recognized that the product of Example 1 exhibited an extremely excellent deodorizing effect, and then the deodorizing effect was in the order of the hot air system of Comparative Example 1 and the heating roller system of Comparative Example 2. It was recognized that

The reason for this is that in Example 1, steam is used as the heat source, but steam has a higher calorific value than hot air, and the ethylene-vinyl acetate copolymer powder melts in a short time. The molten ethylene-vinyl acetate copolymer hardly covers the surface of the activated carbon and enables the activated carbon to be fixed in a short time, and high temperature steam has a function of further activating the activated carbon. It is considered that the activated carbon whose activity has deteriorated is reactivated.

On the other hand, in Comparative Example 1, the fixing time of activated carbon is longer than that in Example 1, and as is clear from the results of the air permeability, the fiber network of the base material and the covering material is The eyes are partially blocked, and the molten ethylene-vinyl acetate copolymer covers the surface of the activated carbon, and the hot air does not contribute very much to the activation of the activated carbon. Further, the fixing time of the activated carbon is long, the molten ethylene-vinyl acetate copolymer further covers the surface of the activated carbon, and as is clear from the results of the air permeability, the heating roller pressurizes the fiber network of the base material and the covering material. It is considered that the eyes were closed further and the adsorption of ammonia decreased.

[0103]

In the first method of the present invention, the functionalizing agent and the powder or granular hot melt resin are provided on the air-permeable film-like or sheet-like substrate having the above-mentioned constitution. Individually spraying or laminating, or spraying and laminating a mixture of the function-imparting agent and powdery or granular hot melt resin, and then using a film-like or sheet-like covering material having air permeability from the top. A feature is that a laminated body is formed by covering and then water vapor is passed through in the thickness direction of the laminated body.

In the first method of the present invention, in particular,
In this way, the functional agent is fixed between the base material and the covering material by allowing water vapor to pass through in the thickness direction of the above-mentioned laminate, but the water vapor has a higher calorific value than hot air and is powdery. By directly contacting with a granular hot melt resin, the hot melt resin can be melted in a very short time even at a relatively low temperature to develop adhesiveness, and the base material or coating material is altered or deteriorated. In other words, oxygen in the air may oxidize and deteriorate the base material and the coating material without hot air, but using steam makes it possible to eliminate such an adverse effect. Since it does not oxidatively decompose and does not lose its activity, not only can the functionalizing agent be effectively used, but also the functionalizing agent that is easily oxidatively decomposed can be used. is there.

Further, in the first method of the present invention, not only hot air but water vapor is passed through the laminate in the thickness direction thereof, and is brought into direct contact with powdery or granular hot melt type resin. It is designed to melt the hot-melt resin in an extremely short time even at extremely low temperatures to develop adhesiveness, but by passing water vapor, a diagram of the fiber network in the base material or covering material. Since no rounding occurs and no pressing with a heating roller is required, extremely excellent effects such as remarkable improvement in workability, flexibility and air permeability of the final product are exhibited.

Further, in the first method of the present invention, water vapor is used. When water vapor is used in this way, the temperature of the water vapor can be relatively easily adjusted, and the water vapor can pass through the base material and the coating material. Since the effect of directly conducting heat is very high, the time required to melt the powdery or granular hot melt resin and develop the adhesiveness is extremely short,
In this respect as well, there is almost no deterioration of the function-imparting agent, the activity of the function-imparting agent is maintained, and the efficiency of the function-imparting agent is extremely improved. Since it does not occur, an effect such as obtaining a functional molded body with stable quality can be obtained.

In the second method of the present invention, a mold having a specific shape is filled with a functionalizing agent and a powdery or granular hot melt resin, and then steam is passed from one of the packings to the other. According to the above, the hot-melt resin is melted by heat of water vapor to develop adhesiveness, and the function-imparting agent is formed and fixed in a predetermined shape. The first aspect of the present invention
In addition to the effects of the method, it is possible to obtain the effect of producing a functional molded product having an arbitrary shape.

The functional molded article of the present invention produced by the method of the present invention is suitably used as an adsorption element for an air cleaner, an air conditioner, a deodorizer, etc., and as a result, Various products, such as building materials, desiccants, deodorants, deodorants, fragrances, electromagnetic wave absorbers, water absorbing / humidifying agents, oxygen scavengers, repellents for small animals, insecticides, depending on the type of functionality-imparting agent used. It has the effect that it can be applied as an agent, a bactericidal agent, an antifungal agent or various health tools.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing steps of a first method of the present invention.

FIG. 2 is a cross-sectional view showing a passing state of water vapor according to the first method of the present invention.

FIG. 3 is a perspective view showing steps of a second method of the present invention.

FIG. 4 is a perspective view showing a state where a mixture of a functionalizing agent and powdery or granular hot melt resin is filled in a cylindrical mold in the second method of the present invention.

FIG. 5 is a perspective view showing a passing state of water vapor in the second method of the present invention.

FIG. 6 is a perspective view showing a water vapor passage device suitably used in the second method of the present invention.

[Explanation of symbols]

1 base material 2 Functionality enhancer 3 Hot melt resin 4 coating material 5 Specific shape mold 6 Water vapor inflow section 7 Water vapor outlet 8 cloth S water vapor

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 4C058 AA19 AA23 BB07 JJ02                 4C080 AA05 BB02 BB05 BB07 BB08                       CC01 HH05 JJ06 KK02 LL03                       MM05 NN25 NN26 NN27 NN28                       QQ03                 4F211 AD08 AD16 AG03 AM28 TA03                       TC02 TC20 TD11 TD18 TN24                       TN43 TN48 TN53 TN55 TQ07

Claims (8)

[Claims] 1. A functionalizing agent and a powder or granular hot melt resin are laminated on a breathable film-like or sheet-like substrate, and a breathable film-like or Forming a laminate by covering with a sheet-shaped covering material, then by passing water vapor in the thickness direction of this laminate, the hot-melt resin is melted by the heat of water vapor to develop adhesiveness, A method for producing a functional molded body, comprising fixing the functionalizing agent between the base material and the coating material. 2. A mold having a specific shape is filled with a function-imparting agent and powdery or granular hot melt resin, and steam is passed from one of the filled materials to the other to obtain the hot melt resin. A method for producing a functional molded article, which comprises melting and developing adhesiveness with heat of steam to form and fix the functionalizing agent in a predetermined shape. 3. The functionality-imparting agent and the powdery or granular hot-melt resin are separately laminated or filled, or the mixture of the functionality-imparting agent and the powdery or granular hot-melt resin is laminated or The method for producing the functional molded body according to claim 1 or 2, which is filled. 4. When passing water vapor, the water vapor is sucked from the outflow side opposite to the water vapor inflow side.
4. The method for producing the functional molded body according to any one of items 1 to 3. 5. The functional molded article according to claim 1, wherein the base material and the covering material are at least one kind selected from a cloth body made of natural fibers and / or artificial fibers. Manufacturing method. 6. The functionalizing agent has a deodorizing action, a deodorizing action,
Water absorption / humidity control, electromagnetic wave absorption, sterilization, antifungal, small animal repellent, insecticidal, deoxygenating, aroma, negative ion generation, or far-infrared radiation The method for producing a functional molded article according to claim 1, wherein the functional molded article is a substance that does. 7. The hot melt resin is polyethylene,
7. At least one selected from polypropylene, ethylene-vinyl acetate copolymer, methacrylic resin, polystyrene, styrene-based copolymer, polyisobutylene, polyamide resin or polyester resin.
A method for producing the functional molded body according to any one of 1. 8. A functional molded article manufactured by using the method for manufacturing a functional molded body according to claim 1.