JP2010228176A - Method for producing functional fiber molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a functional fiber molding which allows to properly disperse functional powder to be contained in vegetable fibers used as a main material in the function fiber molding. <P>SOLUTION: In the method for producing the functional fiber molding 16 containing the functional powder 13, the vegetable fibers 11 are used as a main material. The functional powder is scattered over the vegetable fibers. While the vegetable fibers and the functional powder are dispersed, an air current is generated to mix then. By depositing the mixture, the functional powder is dispersed in the inside of the mixture to be contained. After that, the mixture is molded to produce the functional fiber molding. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for producing a functional fiber molded body containing vegetable fiber as a main material and containing functional powder particles.

A functional fiber molded body containing the above plant fiber as a main material and containing functional powder is used as an interior building material such as an inner wall material, a ceiling material, an underfloor material, or a heat insulating material of a building such as a residence. Or used as furniture materials for various furniture.
Such a functional fiber molded body is, for example, a granular (particulate) functionality having various functionalities such as a moisture absorbing / releasing material (humidity adjusting material), a deodorizing agent, an antibacterial agent, and the like. The powder is added to the vegetable fiber and molded.

For example, Patent Document 1 below proposes a humidity-controlling plant fiber board formed by adhering lignocellulosic fibers obtained from plants with a binder and holding a humidity-controlling material inside.
In Patent Document 1, as a method of dispersing and holding the humidity control material in a board, a method of spraying or impregnating lignocellulosic fibers with a liquid binder in which the humidity control material is dispersed, Examples thereof include a method in which a wet material is dispersed in lignocellulose fibers and then a binder is contained, and a method in which lignocellulose fibers, a binder, and a humidity control material are mixed at the same time.

JP 2008-173834 A

  However, in the above-mentioned Patent Document 1, there is no disclosure of a specific mode in which the humidity conditioning material is appropriately dispersed and contained in the board. For example, in the method of spraying or impregnating, the humidity conditioning material It is conceivable that a local bias occurs. Also, in the method of adding the binder after dispersing the above-mentioned humidity conditioning material in the lignocellulose fiber and the method of simultaneously mixing the lignocellulosic fiber, the binder and the humidity conditioning material, how to adjust the humidity in the board. Whether the material is contained in a moderately dispersed manner is not specifically disclosed, and further improvement has been desired.

  The present invention has been made in view of the above circumstances, and in a functional fiber molded body mainly composed of vegetable fibers, functional fibers that can be appropriately dispersed and contained by a simple method. It aims at providing the manufacturing method of a molded object.

In order to achieve the above object, a method for producing a functional fiber molded body according to the present invention is a method for producing a functional fiber molded body containing vegetable fiber as a main material and containing functional powder. In addition, the functional powder particles are sprayed on the plant fibers, and the plant fibers and the functional powder particles are dispersed to generate an air current, thereby mixing them and in the mixed state. By depositing, the functional powder particles are dispersed and contained therein, and then molded to produce a functional fiber molded body.
Here, the functional powder is a powder having various functions such as moisture absorption and deodorization, insect repellent, antibacterial, etc., and is granular, strip-like, particulate, fine particle Including powder and powder.

In the method for producing a functional fiber molded body according to the present invention, a cotton-like defibrated mixture obtained by dispersing the functional powder particles by adding a synthetic resin fiber as a binder to the plant fiber. You may make it carry out with respect to cotton.
In the method for producing a functional fiber molded body in which the functional powder particles are dispersed with respect to the defibrated mixed cotton, after the functional powder particles are dispersed and contained therein, You may make it shape | mold by making it heat-press and harden | cure to board shape.

  In the method for producing any one of the functional fiber molded bodies according to the present invention, before spraying the functional powder particles, a liquid is sprayed on the plant fibers to wet the surface of the plant fibers. You may make it spray this functional granular material in a state.

According to the method for producing a functional fiber molded body according to the present invention, the functional powder particles are dispersed on the plant fibers, and the plant fibers and the functional powder particles are dispersed, while the air current is dispersed. By mixing these and depositing them in the mixed state, the functional powder particles are dispersed and contained therein, so that functional powder particles can be obtained by a simple method. It is possible to produce a functional fiber molded body in which the body is appropriately dispersed and contained. That is, in general, for example, a so-called wet papermaking method in which fibers and powders are dispersed and mixed in fresh water, or between front and back layers formed in a mat shape with plant fibers. The method of interposing so that a granular material may be pinched | interposed was employ | adopted. In the former, a long drying process is required in the later process, or functional powder (manufacturing loss) that is not contained in the functional fiber molded body in the manufacturing process because it is wet is separated. There was a problem that it was difficult to reuse. Moreover, in the latter, as a result of the functional powder body being unevenly distributed within the thickness of the functional fiber molded body, there is a problem that local density difference or thickness difference occurs in the functional fiber molded body and the strength is lowered. .
On the other hand, according to the present invention having the above-described configuration, by generating an air current, the plant fiber and the functional powder are mixed, and the functional powder is deposited in the mixed state. Can be dispersed and contained in the interior, so that functional powder can be appropriately dispersed and contained by a simple method, and a functional fiber molded body can be produced by a dry production method. Can do. Moreover, since it is a dry manufacturing method, the manufacturing loss part of the functional granular material which generate | occur | produces in a manufacturing process can also be reused easily.

  In the method for producing a functional fiber molded body according to the present invention, a cotton-like defibrated mixed cotton obtained by adding a synthetic resin fiber serving as a binder to the vegetable fiber to disperse the functional powder particles. If it carries out with respect to this, it will be in the state which is easy to get entangled in vegetable fiber by adding a synthetic resin fiber and defibrating vegetable fiber with comparatively strong linearity. As a result, by generating an airflow as described above, it becomes easy to capture the functional powder particles dispersed and contained between the plant fibers, and the functional powder particles are in a later step. It is possible to reduce falling off and scattering.

  In the method for producing a functional fiber molded body in which the functional powder particles are dispersed with respect to the defibrated mixed cotton, the functional powder particles are dispersed and contained therein, and then heated. If pressed and cured into a board shape, the functional powder can be dispersed and contained inside as described above, so it is heated and pressed to form a board shape. Even in this case, a local density difference or a thickness difference hardly occurs in the thickness of the board or in the surface area direction, and a relatively homogeneous board can be manufactured.

  In the method for producing any one of the functional fiber molded bodies according to the present invention, before spraying the functional powder particles, a liquid is sprayed on the plant fibers, and the surface of the plant fibers is wetted. Thus, when the functional powder particles are dispersed, the functional powder particles dispersed and contained therein are easily attached to the plant fibers by generating the air flow as described above. Therefore, when carrying out transportation and various processes in the production process, the functional powder can be more effectively reduced from falling off between plant fibers or being scattered by vibrations, etc. The yield of functional powder can be improved by a simple method.

It is a conceptual explanatory drawing for demonstrating a part of one Embodiment of the manufacturing method of the functional fiber molded object which concerns on this invention. It is a conceptual explanatory view for explaining a part of the manufacturing method. It is a table | surface which shows an example of the Example of a functional fiber molded object manufactured using the manufacturing method, and the comparative example with the result of an evaluation test.

Embodiments of the present invention will be described below with reference to the drawings.
FIG.1 and FIG.2 is a conceptual explanatory drawing for demonstrating an example of the manufacturing method of the functional fiber molded object which concerns on this embodiment. FIG. 3 is a table showing an example of the functional fiber molded body manufactured using the manufacturing method and a comparative example together with the results of the evaluation test.

The functional fiber molded body manufactured by the method for manufacturing a functional fiber molded body according to the present embodiment is a functional fiber board 16 formed in a board shape (flat plate shape) as shown in FIG. .
As shown in FIG. 1, the functional fiber board 16 is formed by using vegetable fibers 11 as a main material and adding synthetic resin fibers 12 as a binder to the plant fibers 11 as described later. A functional powder 13 is sprayed on the defibrated mixed cotton 10 and an air flow is generated while dispersing the fibers 11 and 12 and the functional powder 13 in the air flow dispersion step 2 described later. Then, these are mixed and deposited in the mixed state so that the functional powder 13 is dispersed and contained therein, and then heated and pressed through various steps as will be described later. It is shaped into a shape.

The functional fiber board 16 can be used as interior building materials (surface building materials) such as sliding doors, folding doors, hinged doors (door panels), inner walls, partitions, shelves, kitchen panels, ceilings, etc. It can be used as a heat insulating material such as a wall insulation material or a front plate (door) of a storage furniture such as a cabinet, a top plate, a shelf plate, a side plate, a bottom plate, a back plate, or the like.
Moreover, you may make it stick further the decorative sheet, wallpaper, etc. which have the air permeability for surface finishing according to a use aspect suitably on the surface of this functional fiber board 16. FIG.
Further, a plaster board, a wooden board, a resin board, or the like may be further adhered to the back surface of the functional fiber board 16 depending on the usage mode.

Examples of the plant fibers 11 employed in the functional fiber board 16 include bast fibers collected from the bast of plants (for example, the toughness of hemp plants such as kenaf, flax, ramie, cannabis and jute). Fibers collected from the skin), fibers collected from the stems or edges of hemp plants such as Manila hemp and sisal hemp, fibers collected from palm plants such as oil palm and coconut palm, and wood fibers such as pulp Is mentioned.
In particular, if the hemp plant fiber or coconut plant fiber obtained from the hemp plant or coconut plant which is a non-timber resource is adopted as the plant fiber 11 instead of the wood resource that has been sought to be depleted in recent years, The functional fiber board 16 in consideration of environmental resources can be manufactured. Moreover, the fiber extract | collected from such a hemp plant and palmaceous plant has a tensile strength about 2 to 14 times larger than the fiber extract | collected from the conifer and the hardwood used for the conventional fiber board. Therefore, the strength of the functional fiber board 16 itself can be increased more effectively by adopting fibers collected from these hemp plants and palmaceous plants in the functional fiber board 16, so that interior building materials and furniture materials can be obtained. And so on.

In addition, you may employ | adopt the said various fibers in combination of 1 type, or 2 or more types.
Moreover, what is necessary is just to adjust a compounding ratio so that the said vegetable fiber 11 may become a main material, and it is also possible to mix and mix artificial mineral fibers such as rock wool, slag wool, mineral wool, and glass wool. Good.

The vegetable fiber 11 may be a long fiber. For example, the fiber length may be about 6 mm to 2000 mm, preferably about 10 mm to 200 mm, and more preferably about 20 mm to 100 mm.
When the fiber length of the vegetable fiber 11 is shorter than the above range, the fibers are not easily entangled, and the strength and air permeability of the board itself tend to be reduced, and the fiber length is longer than the above range. And, as will be described later, when the mat-like intermediate molded body 14 is formed by the vegetable fiber 11, there is a tendency that it becomes difficult to obtain a predetermined shape.
The average fiber diameter of the vegetable fiber 11 may be 20 μm to 500 μm, preferably defibrated so as to be about 50 μm to 200 μm.
If the average fiber diameter of the plant fiber 11 is smaller than the above range, the bonding area between the fibers increases, so that the strength of the board itself is increased, but the gap between the fibers is reduced, and air permeability is inhibited. Tend to. Moreover, when the average fiber diameter is larger than the above range, the gap between the fibers becomes large and the air permeability becomes high, but the adhesion area between the fibers decreases and the strength of the board itself tends to decrease.

Examples of the synthetic resin fiber 12 as the synthetic resin binder (adhesive component) employed in the functional fiber board 16 include fibers made of a thermoplastic resin such as polyester, polypropylene, polyethylene, polyethylene terephthalate, and nylon, and polylactic acid resin. The fiber etc. which consist of are mentioned. In addition, the fiber length and fiber diameter of the synthetic resin fiber 12 may be the same as those of the vegetable fiber 11. The various synthetic resin fibers 12 may be used alone or in combination of two or more. For example, a polyester resin is used as a core (core component), and nylon, polyethylene, ethylene-vinyl alcohol resin, or the like is used as a sheath. It is good also as the synthetic resin fiber 12 of the core-sheath structure used as the part (sheath component).
When such a synthetic resin fiber 12 is used as a binder, the vegetable fiber 11 is appropriately entangled with each other, and the synthetic resin fiber 12 is melted by hot pressing and then cured, so that the vegetable fiber It functions as a binder for connecting and solidifying 11 together. Thus, an appropriate space | gap can be maintained by using the synthetic resin fiber 12 as a binder.
Moreover, when the synthetic resin fiber 12 having the above-described core-sheath structure is employed, by heating at a temperature at which the core portion does not melt, the vegetable fibers 11 can be connected and solidified while leaving the core portion. The said space | gap can be more effectively ensured by the entanglement of a core part and the vegetable fiber 11. FIG.

In the present embodiment, the synthetic resin fiber 12 and the vegetable fiber 11 are pre-treated in order to facilitate entanglement with each other and to improve the entanglement (capturing properties) of the functional granular material 13 described later. The plant fiber bundle and the synthetic resin fiber bundle are defibrated simultaneously. By passing through such a defibrating process in several stages, the vegetable fiber 11 and the synthetic resin fiber 12 are mixed while being defibrated appropriately, and a cotton-like defibrated mixture (defibrated mixed cotton 10) Is formed. As will be described later, the defibrated mixed cotton 10 is dispersed from the defibrated mixed cotton 10 into the vegetable fiber (piece) 11 and the synthetic resin fiber (piece) 12 by a fiber disperser 22a.
Further, the synthetic resin binder (adhesive component) is not limited to a fibrous one as described above, and a powdery thermoplastic resin binder is employed instead of or in addition to the synthetic resin fiber 12. It may be.
Furthermore, it is not limited to those composed of the above-mentioned thermoplastic resin, but as a powdery binder containing a thermosetting resin such as urea resin, melamine resin, urea-melamine cocondensation resin, phenol resin, epoxy resin, urethane resin Also good.

The blending ratio of the synthetic resin binder (synthetic resin fiber 12 in this embodiment) to the vegetable fiber 11 (ratio of the synthetic resin binder in the total weight in the state where the vegetable fiber 11 and the synthetic resin binder are mixed) is The solid content may be about 10% to 60% by weight, preferably about 20% to 50% by weight. Thereby, it is possible to manufacture a functional fiber board 16 that can sufficiently exhibit the functionality of the functional powder body 13 to be described later without impairing air permeability (moisture permeability), and adhesion between the plant fibers 11. Can increase the sex.
If the ratio of the synthetic resin binder is smaller than the above, the vegetable fiber 11 tends not to be sufficiently solidified by melting and curing the synthetic resin fiber 12 as will be described later. Tend to disperse, the surface hardness decreases, and peeling occurs. Moreover, if the ratio of the synthetic resin binder is larger than the above, the adhesiveness between the plant fibers 11 is enhanced, but the air permeability (moisture permeability) of the board itself tends to be inhibited, and the functions described later. There is a tendency that a gap for capturing the powder 13 between the fibers is not sufficiently secured.

The functional powder body 13 employed in the functional fiber board 16 includes a moisture-controlling material having moisture absorption / release properties, a deodorant having a deodorizing property, an insect repellent having an insect-repelling property, and an antibacterial agent. The antibacterial agent or catalyst which has the property, a natural material, etc. are mentioned, Any things, such as a granular form, a fine piece form, a particulate form, a fine particle form, and a powder form, may be sufficient.
Examples of the humidity control material include charcoal such as charcoal and bamboo charcoal, talc, zeolite, diatomaceous earth, silica gel (preferably B-type silica gel), clay minerals such as montmorillonite and sepiolite, and inorganic materials such as alumina and silica. . Alternatively, the humidity control material may be a particulate polymer moisture absorbing / releasing material (organic polymer moisture absorbing / releasing material). This polymer moisture-absorbing / releasing material has a reversible moisture-absorbing function and moisture-releasing function. For example, a polymer obtained by polymerizing acrylic acid, methacrylic acid or the like as a main component, or a polymer nitrile containing acrylonitrile as a main component. Examples thereof include acrylic resins having a crosslinked structure such as those obtained by hydrolyzing a group.

The particle size of the functional powder 13 is 2.0 mm or less, preferably 500 μm or less.
In the case of producing a board-shaped functional fiber molded body as in the present embodiment, the thickness of the functional powder 13 is generally about 2.0 mm to 12 mm. Increasing the diameter tends to cause local density differences, thickness differences, etc., and the strength of the board may be reduced. Moreover, if the particle size of the functional powder 13 is increased, the dispersibility tends to be reduced in the airflow dispersion step 2 described later.
In particular, if the particle size of the functional powder 13 is 500 μm or less, for example, when a relatively thin board having a thickness of about 2.0 mm to 5.0 mm is manufactured, it is locally applied. Therefore, a relatively uniform board can be manufactured.
The particle size of the functional powder 13 is not particularly limited, but may be 10 μm or more from the viewpoint of handling and cost. Moreover, you may employ | adopt the said various functional granular material 13 combining 1 type, or 2 or more types.
Moreover, it is good also as an aspect which mixes and employ | adopts the functional granular material 13 from which average particle diameter differs, for example, silica gel with a comparatively large particle diameter, a fine powder deodorant, an antibacterial agent, etc.

Next, an example of a method for producing a functional fiber molded body according to the present embodiment will be described with reference to FIGS.
<Functional granular material application process 1>
In this functional granular material spraying step 1, as shown in FIG. 1, the defibrated mixed cotton 10 supplied from the feeder 20 is conveyed to the defibrated mixed cotton 10 while being conveyed via the belt conveyor 21a. Then, the functional granular material 13 is sprayed by the granular material sprayer 21 from above.
It is preferable that the granular material spreader 21 can disperse a substantially fixed amount of the functional granular material 13 on the defibrated mixed cotton 10.
As such a granular material spreader 21, you may make it apply well-known quantitative supply apparatuses of a granular material, such as a vibration feeder and a screw feeder, for example.

In addition, although the application quantity of the said functional granular material 13 can be suitably set according to the usage aspect of a functional fiber molded object, the fabric weight of the disentanglement mixed cotton 10 disperse | distributed so that it may mention later, etc. In the case where the functional fiber board 16 is formed by heating and pressurizing and curing into a board shape as described later, the connection and solidification of the vegetable fiber 11 by the synthetic resin fiber 12 is not hindered. It is preferable to use a spray amount. For ^example, it may be about ^{50g / m 2 ~1000g / m 2} .

Moreover, you may make it spray the liquid 17 with respect to the defibrated mixed cotton 10 containing the said vegetable fiber 11 before spraying the said functional granular material 13 (liquid spraying process). The liquid spreader 27 for spraying the liquid 17 may be a spray type sprayer for spraying the liquid 17 in the form of a mist.
The liquid 17 may be any liquid as long as it is in a liquid form such as water. Alternatively, an adhesive-containing solution 17 in which an adhesive is dissolved or dispersed in water or another solvent may be used. As such an adhesive-containing solution, an acrylic emulsion or the like that has adhesiveness before heating and is dried and cured by heating as described later is preferable. In addition, the pressure-sensitive adhesive-containing solution may be an aqueous emulsion, a starch solution in which processed starch or the like is dissolved, a diluted aqueous paste, or the like.
Alternatively, in place of or in addition to the pressure-sensitive adhesive-containing solution 17 as described above, a silica sol solution may be sprayed in order to improve (or impart) humidity control properties.

The dispersion amount of the liquid 17 can be set as appropriate according to the basis weight of the defibrated mixed cotton 10 dispersed as described later, but at least the fibers 11 exposed on the upper surface of the defibrated mixed cotton 10, The amount of the surface 12 may be sufficiently wet, or may be the amount of drying and curing in the heating and pressing step 3 described later. For example, it may be about 5 g / scale angle (45 g / m ² ) to about 40 g / scale angle (360 g / m ² ).
As described above, the liquid 17 is sprayed on the plant fiber 11 (including the synthetic resin fiber 12 in the present embodiment) before the functional powder 13 is sprayed, so that the surface is wetted. Thereby, the functional granular material 13 to be dispersed is easily attached to the fibers 11 and 12. Therefore, it is possible to prevent the functional powder particles 13 from falling off or scattering due to vibrations or the like during execution of each step described later or during conveyance.

<Airflow dispersion process 2>
Next, the defibrated mixed cotton 10 on which the functional powder particles 13 are dispersed as described above is introduced into the airflow dispersion device 22. The airflow dispersion device 22 generally includes a fiber disperser 22a and an airflow generation mat forming unit. The air flow generation mat forming section includes a pair of blowers 22b and 22b made of a blower, a fan, etc., a mesh conveyor 22c provided on the downstream side (below the fiber disperser 22a), and a lower portion of the mesh conveyor 22c. And a suction line 22d having a suction machine (not shown) such as a blower arranged in
In the fiber disperser 22a, the plant is obtained by rotating the defibrated mixed cotton 10 on which the functional powder particles 13 are dispersed as described above by rotating a roller body provided with a number of scraping blades on the peripheral surface. The functional fibers 11, the synthetic resin fibers 12, and the functional powder particles 13 are dispersed and blown down to be supplied.

As described above, the plant fibers 11, the synthetic resin fibers 12, and the functional powder particles 13 that are dispersed and supplied by dropping are deposited and stacked while being mixed by the airflow action in the airflow generation mat forming portion. To form a mat. That is, the vegetable fiber 11, the synthetic resin fiber 12, and the functional powder 13 that are dispersed and supplied by the fiber disperser 22a are introduced between the pair of blowers 22b and 22b. On the downstream side of the fiber disperser 22a, a substantially horizontal inward and downward airflow is generated by the air blowing action by the pair of blowers 22b and 22b and the suction action by the lower suction line 22d. While the plant fiber 11, the synthetic resin fiber 12, and the functional powder 13 are mixed by the air flow, the mat-like intermediate formed body 14 is formed by being deposited and laminated on the mesh conveyor 22c. The At this time, the air flow is generated so as to be uniform in the width direction (direction orthogonal to the conveyor conveyance direction) so that the formed mat-like intermediate molded body 14 is not uneven in thickness.
In this way, the functional powder 13 is trapped between the fibers 11 and 12 inside the mat-shaped intermediate formed body 14 by mixing and depositing with the airflow. Thus, it is contained in a moderately and uniformly dispersed state.

The basis weight of the fibers 11 and 12 included in the mat-shaped intermediate molded body 14 can be set as appropriate according to the density and thickness of the functional fiber board 16 (see FIG. 2) manufactured in the manufacturing process. It is.
Further, a small amount of the functional powder 13 and the fibers 11 and 12 that have passed through the mesh conveyor 22c are circulated and supplied to the belt conveyor 21a through the circulation line 22e by suction of the suction line 22d. You may make it do.
Alternatively, after collecting a small amount of the functional granular material 13 and the fibers 11 and 12 that have passed through the mesh conveyor 22c by suction of the suction line 22d with a dust collection filter (dust collection cyclone) or the like, The functional granular material 13 and the fibers 11 and 12 may be separated by using a vibration sieve or a classifier or the like, and these may be reused.
In the present embodiment, as described above, the mat-like intermediate molded body 14 is formed by the airflow action, and therefore, the above-mentioned manufacturing loss can be easily circulated and reused. Can do.

<Heating and pressing step 3>
As shown in FIG. 2, while the mat-like intermediate molded body 14 containing the functional powder particles 13 dispersed therein is appropriately transported by the main conveyor 28, as shown in FIG. To introduce. In the heating and pressing machine 23, the synthetic resin fibers 12 are melted and the plant fibers 11 are connected and solidified. The heating and pressing machine 23 can preliminarily press the mat-like intermediate molded body 14 at a relatively low pressure and heat the synthetic resin in order to make the mat-shaped intermediate molded body 14 have a certain degree of shape retention. Any material can be used as long as it can melt the fiber 12.
<Ventilation cooling process 4>
A suction unit (not shown) such as a blower from below while the mat-like intermediate molded body 14 that has been heated and pressed by the heating and pressing machine 23 and is led out from the heating and pressing machine 23 is being conveyed through the mesh conveyor 24a. Is sucked by the suction means 24 provided with the air to cool the mat-like intermediate molded body 14 with air at normal temperature. Thereby, the synthetic resin fiber 12 melted as described above is cured, and the functional fiber mat 15 is formed. In this state, it will be in the state hardened to such an extent that it can be carried.
<Preliminary cutting step 5>
The functional fiber mat 15 cured to some extent as described above is cut into a predetermined size by the cutting machine 25 so that the functional fiber mat 15 can be introduced into the hot press machine 26 in the hot press process 6 described later. To do.

<Hot press (heat pressurization) process 6>
Next, the functional fiber mat 15 is introduced into a hot press machine (hot press machine) 26 having a pair of press plates, and hot press (heat press) is performed. The conditions during the hot pressing, that is, the pressing pressure, the pressing time, and the press mold surface temperature, are the weight of each fiber 11, 12 included in the functional fiber mat 15 and the density of the functional fiber board 16 after molding. It can be appropriately set according to the thickness of the plate, the type of the synthetic resin binder (melting temperature, curing temperature, etc.) and the content.
Moreover, you may make it heat-press so that the density of the functional fiber board 16 after shaping | molding may be 500 kg / m < ³ > or more and 1200 kg / m < ³ > or less at the time of the said heat press. As a result, the strength of the functional fiber board 16 after molding can be increased and the air permeability thereof is not hindered, so that the functionality of the contained functional powder 13 can be sufficiently exhibited. The fiber board 16 can be manufactured.

When the density of the functional fiber board 16 is less than 500 kg / m ³ , the surface hardness and strength of the functional fiber board 16 tend to decrease, and the holding power of nails, wood screws, and the like tends to decrease. is there. Further, when the density of the functional fiber board 16 is more than 1200 kg / m ³ , the air permeability of the functional fiber board 16 tends to be lowered.
After performing the hot press as described above, the mold is removed and appropriately cut into a predetermined size to produce the functional fiber board 16. The functional fiber board 16 molded in this way becomes a breathable porous (matrix) state due to the entanglement of the vegetable fibers 11 connected and solidified by the synthetic resin fibers 12 as described above, and the entanglement is achieved. As described above, the functional granular material 13 is appropriately dispersed between the plant fibers 11 to be captured and contained in the functional fiber board 16.

As mentioned above, according to the manufacturing method of the functional fiber molded object which concerns on this embodiment, the said vegetable fiber 11, the synthetic resin fiber 12, and the functional granular material 13 are mixed by generating an airflow, By depositing in the mixed state, the functional powder 13 can be dispersed and contained therein, so that the functional powder 13 can be appropriately dispersed and contained by a simple method. In addition, the functional fiber board 16 can be manufactured by a dry manufacturing method.
Further, in the present embodiment, the functional powder particles 13 are sprayed on the cotton-like defibrated mixed cotton 10 which has been defibrated by adding the synthetic resin fiber 12 serving as a binder to the vegetable fiber 11. Therefore, the vegetable fiber 11 having relatively high linearity can be easily entangled by adding the synthetic resin fiber 12 and defibrating. As a result, by generating the air flow as described above, the functional powder 13 dispersed and contained therein can be easily captured between the plant fibers 11, and the functional powder 13 It is possible to reduce dropping or scattering in the process.
Furthermore, as described above, since the functional granular material 13 can be appropriately dispersed and contained therein, when the functional fiber board 16 is formed by heating and pressing, the functional fiber board Within the thickness of 16 and in the surface area direction, a local density difference, a thickness difference, etc. hardly occur, and a relatively homogeneous board 16 can be manufactured.

In addition, although each said process has illustrated the aspect which processes and shape | molds an intermediate molded object continuously, conveying by each conveyor and each apparatus, such as the main conveyor 28, for example, each intermediate | middle made into the stationary state It is good also as an aspect which moves each apparatus with respect to a molded article and performs each process. In this case, it may be sequentially conveyed or transferred by a conveyor or other transfer means for the next step.
Moreover, in the said airflow dispersion | distribution process 2, the aspect which forms the mat-like intermediate molded object 14 by disperse | distributing and depositing the defibrated mixed cotton 10 which mixed the synthetic resin fiber 12 with the vegetable fiber 11, and the functional granular material 13 That is, instead of or in addition to the mode in which the binder is the synthetic resin fiber 12, the above-mentioned powdery binder may be added to the vegetable fiber 11 and mixed. In this case, as a mode in which a powdery binder is added in advance to the functional powder 13 and the powdered binder is sprayed together with the functional powder 13 in the functional powder spraying step 1. Also good. Even in such an embodiment, in the subsequent air flow dispersion step 2, the powdered binder and the functional powder 13 are appropriately dispersed and contained by being deposited and laminated while being mixed with the vegetable fiber 11. Thus, the mat-like intermediate formed body 14 can be formed.
Or it is good also as an aspect which manufactures the functional fiber board 16 by, for example, normal temperature press, without including the above synthetic resin binders.

Furthermore, in the present embodiment, in the air flow dispersion step 2, the pair of blowers 22b and 22b generate a blow air flow substantially inward in the horizontal direction to mix the fibers 11 and 12 and the functional powder 13. On the other hand, although the aspect which accumulates and laminates these in the state mixed by the attraction | suction effect | action by the attraction | suction airflow produced by the lower suction line 22d is illustrated, it is not restricted to such an aspect. For example, without providing the lower suction line 22d, a pair of blowers 22b and 22b generate a blowing airflow substantially inward in the horizontal direction, and the fibers 11 and 12 and the functional powder 13 are mixed. Alternatively, the mat-like intermediate molded body 14 may be formed by stacking and stacking by dropping its own weight.
Furthermore, in the present embodiment, in the airflow dispersion step 2, an example is illustrated in which the defibrated mixed cotton 10 on which the functional powder particles 13 are dispersed is dispersed by the fiber disperser 22a. It is not restricted to a certain aspect. For example, the air flow generation mat is applied to the plant fibers 11 and the synthetic resin fibers 12 dispersed in advance in the form of fiber pieces after the functional powder particles 13 are sprayed or while the functional powder particles 13 are sprayed. It is good also as an aspect which drops and supplies these to a formation part.

  Further, as described above, after the defibrated mixed cotton 10 is dispersed and deposited in the airflow dispersion step 2 to form the mat-shaped intermediate molded body 14, before the heating and pressing step 3, the mat-shaped intermediate molding 10 is performed. The body 14 may be introduced into a needle punching machine to perform a needle punching process. Thereby, each fiber 11 and 12 contained in this mat-like intermediate molded object 14 can be entangled (entangled) more, and the intensity | strength of the functional fiber molded object after shaping | molding can be improved. In addition, when performing the needle punching process in this way, it is considered that the functional powder 13 dispersed and contained therein is likely to fall off or scatter, so the liquid spraying process is performed. You may make it do. Thereby, since the adhesiveness of the functional granular material 13 with respect to each fiber 11 and 12 is improved, even when intense vibration like a needle punching process is applied, the functional granular material 13 is dropped or scattered. Etc. can be effectively reduced.

Furthermore, in the present embodiment, after the functional fiber mat 15 is formed as described above, an example in which the functional fiber mat 15 is formed into a board shape by heating and pressurizing is illustrated. However, the present invention is not limited, and a non-board-shaped molded body having irregularities and curved surfaces may be manufactured.
Furthermore, for example, the mat-shaped molded product having a relatively low density, that is, the functional fiber mat 15 may be grasped as the functional fiber molded product without heating and pressing.
Moreover, in this embodiment, the functional fiber mat 15 which passed through the heating and pressing step 3 and the ventilation cooling step 4 is cut in the preliminary cutting step 5, introduced into the hot press machine 26, and illustrated as an example of heating and pressing. However, without passing through the heating and pressing step 3, the air cooling step 4 and the preliminary cutting step 5, for example, the mat-like intermediate formed body 14 is introduced into the heating and pressing roller, It is good also as an aspect which performs a heating-pressing process continuously.

Next, an example of a functional fiber molded body manufactured using the method for manufacturing a functional fiber molded body according to the present embodiment and a comparative example will be described with reference to FIG. To do.
In each example shown in FIG. 3, jute is adopted as the vegetable fiber 11, and polyester fiber having a core-sheath structure in which the sheath portion has a melting temperature of 110 ° C. is used as the synthetic resin fiber 12. The above-mentioned defibrated mixed cotton 10 blended by weight% was used.
Moreover, in each example shown in FIG. 3, B-type silica gel as a humidity control material was employed as the functional powder 13 and an average particle size of 30 μm was used.
Further, in each example shown in FIG. 3, the press conditions in the heating and pressurizing step 10 are as follows: the distance between press dies (spacer (distance bar) thickness) is 2.5 mm, the press temperature is 150 ° C., and the press pressure is 25 kg / cm ^2. (About 2.45 MPa), the pressing time was set as 180 seconds, the specific gravity of the board after molding was set to about 0.65, and the thickness was set to 2.5 mm.

Example 1
For the defibrated mixed cotton 10, the functional powder material dispersion step 1 is performed at a dispersion amount of about 200 g / m ^{2 on the} silica gel, and then the air flow dispersion step 2 is performed. After the mat-like intermediate molded body 14 was formed so that the entire basis weight of 12 was about 1500 g / m ² , the board according to Example 1 was obtained through the steps 3 to 6 described above.
(Example 2)
In addition to the process of Example 1, the liquid spraying process was performed before the functional powder particle spraying process 1. In the liquid spraying step, the spray amount of the liquid (water) 17 by the liquid sprayer 27 was set to a spray amount of about 150 g / m ² .

(Comparative Example 1)
The defibrated mixed cotton 10 is dispersed and deposited only by the fiber disperser 22a, that is, in a state where no airflow is generated in the airflow generation mat forming portion, so that the basis weight is about 1500 g / m ^2. The mat body was divided into two in the thickness direction and sprayed so as to sandwich the silica gel between the upper and lower mat body layers. The silica gel was sprayed almost uniformly so that the spraying amount was about 200 g / m ² .
Next, the steps 3 to 6 were performed on the mat body sandwiched with the silica gel to obtain a board according to Comparative Example 1.

The following evaluation tests were performed on the boards of Examples 1 and 2 and Comparative Example 1.
(Evaluation test) 1) Granule yield measurement test In the board production line in Example 1 and Example 2 above, the amount of silica gel recovered relative to the amount of silica gel sprayed (recovery of silica gel dropped due to falling off, scattering, etc.) The amount ratio was calculated as the loss rate in each production line, and the powder yield rate was calculated from the loss rate.
The results are as shown in the table of FIG.
About Example 2, since the liquid spraying step was performed and water was sprayed as described above, the adhesion of silica gel to silica gels and each fiber was improved, and the recovered amount of silica gel was reduced (that is, silica gel The yield rate (82%) greatly exceeded that of Example 1 (70%).
On the other hand, also in Example 1, as a result of the silica gel being almost uniformly dispersed and contained in the airflow dispersion step 2, the silica gel is trapped between the fibers 11 and 12, and the dropout and scattering during transportation are not so much. It was not recognized, and the result was generally good.
In Comparative Example 1, since the silica gel is sandwiched between the upper and lower layers of the mat body, almost no dropout or scattering of the silica gel was observed, and therefore the powder yield measurement test was omitted. did.

(Evaluation test) 2) Weight variation measurement test (uniformity)
The boards of Examples 1 and 2 and Comparative Example 1 were cut into small-area test pieces, the weight of each test piece was measured, and the weight difference per square meter was calculated as the weight variation.
The results are as shown in the table of FIG.
About Example 1 and Example 2, as above-mentioned, in the airflow dispersion | distribution process 2, since the functional powder body 13 is disperse | distributed substantially uniformly, it contains in the plane area direction of the shape | molded board. The variation in weight was relatively small, and good results were obtained.
On the other hand, for Comparative Example 1, as described above, since the silica gel is sandwiched between the upper and lower layers of the mat body, a local density difference has occurred in the plane area direction of the molded board. As a result, the weight variation was relatively large.

(Evaluation test) 3) Peel strength test Peel strength according to the method prescribed | regulated to JISA5905 (fiber board) with respect to each test body obtained from the board of the said Example 1, Example 2, and the comparative example 1. A test was conducted.
The results are as shown in the table of FIG. 3, and both Example 1 and Example 2 are defined in JIS standards as the quality of MDF (Medium Density Fiberboard) which is a general building material. It became 0.3 MPa or more which is a reference value of the obtained peel strength.
On the other hand, for Comparative Example 1, as described above, since the silica gel is sandwiched between the upper and lower layers of the mat body, it is considered that the physical properties became non-uniform within the thickness, and the peel strength was compared. The result was smaller.

As described above, according to the method for producing a functional fiber molded body according to the present embodiment, the uniformity of the molded board can be improved by a simple method, and the functional granular material 13 can be appropriately used. Since it can be dispersed and contained inside, the uniformity in the plane area direction and the thickness direction of the board is improved, and the strength can be improved.
Moreover, by performing the liquid spraying step as in Example 2 above, it is possible to effectively reduce the falling off or scattering of the functional powder 13 in the production line, and the functional powder can be obtained by a simple method. The yield of the granules 13 could be improved.
In addition, the said Example 1 and Example 2 have shown the example manufactured using an example of the manufacturing method of the functional fiber molded object which concerns on this embodiment, respectively, and the functional fiber molded object which concerns on this embodiment is shown. As described above, various modes of the manufacturing method are possible, and the manufacturing method is not limited to these examples.

DESCRIPTION OF SYMBOLS 10 Disentanglement cotton 11 Plant fiber 12 Synthetic resin fiber 13 Functional powder 15 Functional fiber mat (functional fiber molding)
16 Functional fiber board (functional fiber molding)
17 liquid

Claims (4)

A method for producing a functional fiber molded body containing vegetable fiber as a main material and containing a functional powder,
The functional powder particles are dispersed on the plant fibers, and the plant fibers and the functional powder particles are dispersed to generate an air current, thereby mixing them and depositing them in the mixed state. A method for producing a functional fiber molded body, characterized in that the functional powder body is dispersed and contained therein and then molded to produce a functional fiber molded body. In claim 1,
Sprinkling of the functional powder is performed on a cotton-like defibrated mixed cotton obtained by adding a synthetic resin fiber as a binder to the plant fiber and defibrated. Production method. In claim 2,
A method for producing a functional fiber molded body, wherein the functional powder body is dispersed and contained therein, and then heated and pressurized to be cured into a board shape. In any one of Claims 1 thru | or 3,
Before spraying the functional powder, the liquid is sprayed on the vegetable fiber, and the functional powder is sprayed in a state where the surface of the vegetable fiber is wet. A method for producing a fiber molded body.

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