JP3023748B2 - Carbon-glass composite carbonized sheet member and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carbon-glass composite carbonized sheet member, and more particularly, to a sound absorbing wall or ceiling member utilizing the charcoal charcoal, a vibration member for a speaker, a separator member for a fuel cell, a deodorant, and Odor prevention mask Antibacterial and antibacterial sheet material Adsorbing material for oil and harmful substances Filter for air purification and exhaust gas purification Carbon-glass composite carbonized sheet material widely used as an industrial material such as soil reforming base material It relates to the manufacturing method.

[0002]

2. Description of the Related Art Conventionally, as a carbonized sheet member used for these industrial materials, a carbonaceous thin plate obtained by subjecting wood powder to a baking treatment and carbonizing it has been known. When a carbonaceous thin plate is manufactured from wood flour, it is manufactured in steps as shown in the following two examples (manufacturing example A and manufacturing example B).

Production Example A 1) First, wood powder consisting of spruce, cedar, fir, hemlock, hinoki, pine, bamboo and the like having a particle size of 0.2 to 0.6 mm is calcined at 200 to 800 ° C. in a furnace and carbonized. To produce charcoal powder having a particle size of 0.05 to 0.15 mm. 2) To 100 parts by weight of the produced charcoal powder, 150 to 200 parts by weight of a carbonaceous filler composed of coke and graphite and a thermosetting binder 60 to 20 composed of a phenol resin.
0 parts by weight are mixed and kneaded. 3) After completion of kneading, according to the purpose of use of the carbonaceous thin plate, vertical 500-900 mm x horizontal 500-900 mm x thickness 2
It is formed into a 5 mm thin plate. 4) After heating and hardening the above-mentioned thin plate at 80 to 140 ° C., it is again subjected to firing and carbonization at 500 to 800 ° C. in a furnace, and 400 to 700 mm long × 400 to 700 mm wide.
A carbonaceous thin plate having a thickness of 1.5 to 3 mm is produced.

Production Example B 1) First, wood powder consisting of spruce, cedar, fir, tsuga, hinoki, pine, bamboo and the like having a particle size of 0.2 to 0.6 mm is calcined at 200 to 800 ° C. in a furnace and carbonized. To produce charcoal powder having a particle size of 0.05 to 0.15 mm. 2) A liquid slurry is prepared by mixing 5 to 40 parts by weight of a carbonaceous filler composed of coke and graphite and 500 to 1000 parts by weight of a dispersion medium composed of water with 100 parts by weight of the produced charcoal powder. 3) A paper sheet is formed from the prepared slurry in the same manner as paper paper to form a sheet having a thickness of 0.2 mm. 4) The formed sheet is impregnated with a phenol resin as a binder to form a semi-cured sheet. 5) Formed semi-cured sheet at 100-120 ° C
And pre-cured. 6) The cured sheet is again fired and carbonized at 600 to 800 ° C. in a furnace, and is 500 mm long × 500 mm wide.
X Produce a carbonaceous thin plate having a thickness of 0.1 mm.

[0005]

In the above-mentioned method for producing a carbonaceous sheet, the number of production steps required to obtain the carbonaceous sheet is extremely large, and naturally, a great deal of labor and cost are required. These will be described below.

1. As is clear from the above description of the process, in the conventional manufacturing process, the “firing and carbonization” process must be performed twice before and after, and furthermore, the final (second) firing and carbonizing process is performed.
In the carbonization process, there is a problem that the firing and carbonization process has to take a long time of about 20 to 40 hours in order to prevent warping, twisting, cracking, etc. in the thin plate. In order to form the charcoal powder into a thin sheet, it is necessary to introduce an expensive molding machine or equipment for papermaking. 3. The thin sheet manufactured in such a process is (Second) baking and carbonization treatment is performed. At this time, it is necessary to prevent cracks and chips from occurring in the thin plate in the moving / transporting process. It is necessary to perform a temporary pressing process with a thermosetting adhesive (expensive as a binder). 4. A further decisive weakness is that the thin sheet made of charcoal powder is made of other materials. Since the intensity is not made, very fragile, it is limited in application, and the like.

[0007] The present invention solves the above-mentioned problems of the conventional carbonaceous sheet, and is a charcoal-glass composite carbonized sheet member that is easy to manufacture, low cost, and has high strength. The purpose is to provide. That is, the three objects of (1) reducing the number of steps required for manufacturing, (2) shortening the firing and carbonizing time, and (3) increasing the strength of the member are solved.

[0008]

SUMMARY OF THE INVENTION The carbon-glass composite carbonized sheet of the present invention and the method for producing the same are intended to be solved by a method completely different from the conventional production process. That is, in the present invention, the production process is based on a completely new idea of adhering a glass fiber substrate and wood flour, and 1) a sheet substrate and wood flour adhering process, and 2) a firing / carbonization process. It is possible to configure with only two steps.

In other words, the conventional process is a process in which wood powder is once carbonized by a firing and carbonizing process to obtain charcoal powder, which is solidified to form a thin plate, and then subjected to the firing and carbonizing process again. Therefore, a large number of steps and unnecessary manufacturing costs were required, but in the present invention, a sheet base material is prepared to be a thin plate from the first step, and one or both sides of the base material are prepared. The sheet is completed only by sticking the wood flour, and thereafter, the sheet is simply fired and carbonized to complete the process.

Further, in the production method of the present invention, since charcoal and glass fibers form a matrix, not only no warping, twisting, and cracking occur even after firing and carbonization, but also dimensional stability. In the transfer / transportation process to the calcination / carbonization treatment, the sheet made of the glass fiber base itself has the flexibility, so that it is not cracked or chipped.

[0011] The carbon-glass composite sheet member of the present invention comprises:
It is characterized in that charcoal and glass are formed in a matrix in a sheet made of a glass fiber base material.

In the method for producing a carbon-glass composite sheet member of the present invention, wood powder is adhered to a glass fiber base material, and then baked and carbonized. Are formed in a matrix.

The wood flour may be a mixture of wood flour and a binder.

The mixing ratio of the wood powder to the binder is 10: 1 to 1 by weight.
It may be 1:10.

[0015]

After the wood powder is adhered to the glass fiber substrate, it is baked and carbonized, and the baked and carbonized charcoal and the molten glass are combined with a carbon-glass composite carbonized sheet formed in a matrix. Become.

The carbon-glass composite carbonized sheet does not warp, twist, or crack at all even after firing and carbonizing.

Further, since wood powder is adhered to the glass fiber base material, the glass fiber base material itself has flexibility. No cracking or chipping.

As wood powder to be adhered to a glass fiber substrate,
When a mixture of wood powder and a binder is used, the wood powder does not fall off or scatter from the glass fiber substrate before and during the firing and carbonization treatments.

[0019]

EXAMPLE The glass fiber base material used in the present invention adheres to the surface, and further, wood powder enters into the inside, and is fired.
After the carbonization treatment, any material may be used as long as carbonized charcoal and molten glass are formed in a matrix, and examples thereof include a nonwoven fabric, a mesh sheet, a lattice sheet, and a plain woven cloth. The glass fiber substrate has a thickness of 0.1 to 0.5 for reasons such as adhesion of wood powder, productivity, and economy.
mm, weight 25-100 g / m ² , tensile strength (vertical)
It is set to 2.7 to 8.0 kg / 15 mm width.

The wood powder to be adhered to the glass fiber base material is effective regardless of wood waste materials, especially thinned wood materials which are well-quantified and the tree species are clearly defined, regardless of the type of wood, and regardless of uneven shape. Any material that can be reused and carbonized by the firing treatment may be used, and examples thereof include spruce, cedar, hinoki, hemlock, and fir. In addition, the particle size of the wood powder is 0.1% because of its adhesion to the glass fiber base material, easy carbonization, waste material utilization, productivity, and economic efficiency.
About 1 mm.

Further, the wood powder is sufficiently adhered to the glass fiber base material, and further impregnated into the inside thereof.
From the viewpoint of preventing the wood powder from falling off or scattering from the glass fiber base material until the carbonization treatment and during the firing and carbonization treatments, it is preferable to use a mixture of the wood powder and the binder. Examples of the binder mixed with the wood powder include PVA (polyvinyl alcohol), aqueous vinyl urethane, and the like. The mixing ratio of the binder is increased when a dense carbonized sheet is required. If a coarse carbonized sheet is required, the ratio of the binder may be increased, for example, the ratio of the binder may be increased, and the carbon-glass composite carbonized sheet member may be appropriately selected according to the degree of carbonization. : About 1 to 1:10.

Next, specific examples of the present invention will be described together with comparative examples.

Example 1 FIG. 1 is a schematic process diagram of an example of a method for producing a carbon-glass composite carbonized sheet of the present invention.

In FIG. 1, 1 is 0.5 mm in thickness and 75 g in weight.
/ M ^2, shows the tensile strength (longitudinal) 8.0 kg / 15 mm width of the nonwoven fabric (Nippon Vilene Co., Ltd., trade name Kyumurasu nonwoven) a glass fiber base material made of. In the illustrated example, the long glass fiber substrate 1 is wound around a core in a roll shape.

2 is a mixture (liquid) of wood flour and a binder 3
1 shows an impregnation tank for accommodating. In this embodiment, spruce having a particle size of 0.1 to 1 mm and an average particle size of 0.5 mm is used as wood flour, and 10% of PVA (polyvinyl alcohol) is used as a binder. 14.7: 100 (about 60: 100 by volume)
And

The glass fiber substrate 1 is passed through a mixture (liquid) 3 of wood powder and a binder in the impregnation tank 2 while rewinding the long glass fiber substrate 1 so that the glass fiber substrate 1 The sheet 4 to which the mixture 3 was adhered and the mixture of the wood flour and the binder was adhered was produced.

The passage time in the impregnation tank 2 was set to about 2 to 5 minutes while grasping the state of impregnation of the glass fiber substrate with the wood powder.

Therefore, when the glass fiber substrate 1 passes through the mixture 3 of the wood flour and the binder in the impregnation tank 2, the mixture 3 adheres to the glass fiber substrate 1 and further impregnates and adheres to the inside. Becomes

Reference numeral 5 denotes, for example, an electric furnace for baking and carbonizing a sheet 4 prepared by adhering a mixture 3 of wood powder and a binder to a glass fiber substrate 1. The electric furnace 5 is provided with a temperature gradient. The temperature gradually rises from room temperature near the entrance side of the glass fiber substrate 1, and 500 to 8 near the center of the electric furnace 5.
The temperature is set so as to be as high as 00 ° C. and to decrease toward the outlet. Since the atmosphere in the electric furnace 5 requires an air-blocking atmosphere, a nitrogen gas curtain may be provided at each of the entrance and exit of the electric furnace 5.

Since wood flour generates a gas containing a large amount of tar when carbonized, it necessarily has an oxygen concentration of 1%.
Since it is kept low, the consumption of nitrogen gas at the entrance and exit of the electric furnace 5 does not become large.

Then, a sheet 4 prepared by adhering a mixture 3 of wood flour and a binder to the glass fiber base material 1 was heated to an electric furnace temperature of 500 to 800 ° C.
While passing through the electric furnace 5 set at 00 ± 10 ° C.,
The wood flour and the binder are carbonized by firing and carbonizing, and the charcoal 6 of the wood flour and the molten glass 7 of the glass fiber are matrixed in a sheet made of a glass fiber base material as shown in FIGS. The carbon-glass composite carbonized sheet member 8 formed in the shape was prepared.

The passage time in the electric furnace 5 was set to 2 hours.

The strength of the produced carbon-glass composite carbonized sheet member 8 was measured, and the results are shown in Table 1. Table 1 shows the number of steps required for manufacturing the carbon-glass composite carbonized sheet member of the present invention. And the time required for carbonization.

Generally, the produced carbon-glass composite carbonized sheet member 8 is cut to have predetermined lengths and widths according to applications.

In FIG. 1, reference numeral 9 denotes a guide roll disposed before and after the impregnation tank 2, and reference numeral 10 denotes a guide roll disposed before and after the electric furnace 5, respectively.

Comparative Example 1 FIG. 3 is a process schematic diagram of a method for manufacturing a carbonized sheet member in the conventional manufacturing example A.

First, a particle size of spruce material of 0.2 to 0.2
0.6 mm and an average particle size of 0.4 mm wood flour 11 at a temperature of 80
In a muffle furnace 12 set at 0 ° C., a baking and carbonizing treatment is applied to obtain a particle size of 0.05 to 0.15 mm and an average particle size of 0.1 mm.
13 charcoal powder was prepared. The firing and carbonization time was set to 2 hours.

Next, charcoal 13 powder, filler 14,
A binder (phenolic resin P-70, manufactured by Aika Co., Ltd., product name: P-70) 15 mixed (weight) ratio 1: 1.5: 0.
After being weighed so as to be 6, the mixture was put into a mixing / kneading machine 16, and after charcoal, filler and binder were kneaded, the mixture was put into a thin plate manufacturing machine 17 composed of an extruder.

Then, a thin plate manufacturing machine (extruder) 17
Extruded from the die 18 of 2mm thick and 500m wide
m and formed into a thin plate 19 having a length of 500 mm.

The temperature of the formed thin plate 19 is gradually raised from the room temperature near the entrance side, reaches a high temperature of 500 to 800 ° C. near the center of the furnace, and passes through the electric furnace 20 set so as to decrease the temperature toward the exit. After passing through, the thin plate 19 is again subjected to a baking and carbonizing treatment to produce a carbonized sheet 21. The process in the electric furnace 20 is mainly for carbonizing the remaining filler and binder in the thin plate 19. This is because if organic components such as a filler and a binder remain in the carbonized sheet 21, the use temperature conditions and the like as a product are limited, and the use is limited, which is disadvantageous.

The passage time in the electric furnace 20 was 24 hours.

The strength of the carbonized sheet 21 was measured, and the results are shown in Table 1. Table 1 shows the number of steps required for producing the carbonized sheet member in the production method A and the time required for carbonizing. .

Comparative Example 2 FIG. 4 is a process schematic diagram of a method for manufacturing a carbonized sheet member in the conventional manufacturing example B.

First, a particle size of spruce material of 0.2 to 0.2
0.6 mm and an average particle size of 0.4 mm wood flour 31 at a temperature of 80
In a muffle furnace 32 set at 0 ° C., a baking and carbonizing treatment is applied to obtain a particle size of 0.05 to 0.15 mm and an average particle size of 0.1 mm.
Charcoal 33 powder was produced. The firing and carbonization time was set to 2 hours. The wood powder baking / carbonization process is the same as the wood powder carbonization process of Comparative Example 1.

Next, mixing (weight) ratio of charcoal 33 powder, fibrous filler and water as a dispersion medium is 1: 0.2:
The slurry was weighed so as to be 10, and a slurry (liquid) 34 was prepared by mixing them.

A charcoal-filler thin plate 35 is formed in the same manner as that of making Japanese paper from the slurry 34. Subsequently, the thin plate 35 is impregnated with a binder (phenolic resin P-70, manufactured by Aika Co., Ltd.). , Thin plate 35 up and down 1
A semi-curing process was performed between the pair of hot-presses 36 to produce a thin plate 37 in a semi-cured state. It is to be noted that the semi-cured thin plate 37 is formed by the hot press 36 because if not semi-cured, the thin plate itself is very fragile and easily cracks and chips.
This is because the subsequent manufacturing operation becomes difficult.

The temperature of the prepared semi-cured thin plate 37 is gradually increased from room temperature near the entrance side, and 500 mm near the center of the furnace.
To a high temperature of about 800 ° C. and passed through an electric furnace 38 set to decrease the temperature toward the outlet.
The carbonized sheet 39 was again produced by performing a firing and carbonizing treatment. The process in the electric furnace 38 is mainly for carbonizing the remaining filler and binder in the thin plate 37.
This is because if organic components such as a filler and a binder remain in the carbonized sheet 39, the use temperature conditions and the like as a product are limited, and the use is limited, which is disadvantageous.

The passage time in the electric furnace 38 was 36 hours. The firing and carbonizing treatment in the electric furnace is the same as the firing and carbonizing treatment in the electric furnace of Comparative Example 1.

The strength of the carbonized sheet 39 thus produced was measured, and the results are shown in Table 1. Table 1 shows the number of steps required for producing the carbonized sheet member and the time required for carbonizing in the production method B. .

[0050]

[Table 1]

As is evident from Table 1, in the examples of the present invention, the number of steps required for the production is small, and the time required for carbonization is extremely short, whereas Comparative Examples 1 and 2 of the conventional method require the production. Not only the number of steps is large, but also the time required for carbonization is extremely long. Further, the carbonized sheets produced in the examples of the present invention have excellent strength, whereas the carbonized sheets produced in Comparative Examples 1 and 2 of the conventional method have extremely low strength. Therefore, in the present invention, there is an advantage that a high-strength carbon-glass composite carbonized sheet can be continuously manufactured, and it can be seen that the sheet can be manufactured extremely easily and inexpensively from the viewpoint of manufacturing cost.

Generally, the softening point of glass is 400 to 500.
It is about ° C. The firing and carbonizing temperature of the wood powder is 500
８００800 ° C., and in this temperature range, the glass starts to soften or melt. That is, by appropriately setting the firing / carbonization temperature and heating to that temperature, a matrix of charcoal and glass is formed.

Even if the wood powder is carbonized and changed into charcoal, the charcoal powders do not fuse with each other. By melting, a strong bond is obtained:
This is called sintering). Therefore, a carbonized sheet made only of wood flour and a binder (because the binder itself is only carbonized by high-temperature heating) is generally very brittle in terms of strength.

FIG. 5 shows an acoustic panel 41 manufactured using the carbon-glass composite carbonized sheet member manufactured by the method of the present invention. The acoustic panel 41 is a laminate of a back plate 42, a carbon-glass composite carbonized sheet member 43, and a decorative plate 44.

FIG. 6 shows a speaker cone 45 manufactured using the carbon-glass composite carbonized sheet member manufactured by the method of the present invention. The speaker cone 45 is constituted by a carbon-glass composite carbonized sheet member 46.

FIG. 7 shows a sewage purification filter 47 produced using the carbon-glass composite carbonized sheet member produced by the method of the present invention. The purifying filter 47 is constituted by a carbon-glass composite carbonized sheet member 48,
Is obtained as purified water 50 after passing through the washing filter 47.

[0057]

According to the carbon-glass composite carbonized sheet member of the present invention, the carbon-glass composite carbonized sheet itself has excellent high strength because it is a sheet in which charcoal and glass are formed in a matrix. It has effects that it cannot be used with conventional carbonized sheets, and can be widely used as industrial materials such as building members.

Further, according to the method for producing a carbon-glass composite carbonized sheet member of the present invention, an excellent high-strength carbon
Compared with the conventional method, the glass composite carbonized sheet member can be reduced in labor required for the number of steps required for production, can be fired, and the carbonization time can be shortened. Having.

As wood powder to be attached to a glass fiber substrate,
When a mixture of wood flour and binder is used, the wood flour can be prevented from falling off or scattered from the glass fiber base material before and during the firing and carbonization treatment, and the charcoal adheres strongly to the glass. Can be done.

[Brief description of the drawings]

FIG. 1 is a schematic process diagram of one embodiment of a method for producing a carbon-glass composite carbonized sheet member of the present invention;

FIG. 2A is a perspective view of one example of a carbon-glass composite carbonized sheet member produced by the production method of the present invention, FIG. 2B is an enlarged cross-sectional view of a main part thereof,

FIG. 3 is a schematic view of a process of one example of a conventional method for producing a carbonized sheet;

FIG. 4 is a process schematic diagram of another example of a conventional method for producing a carbonized sheet,

FIG. 5 is an acoustic panel manufactured using the carbon-glass composite carbonized sheet member manufactured by the manufacturing method of the present invention;

FIG. 6 shows a speaker cone manufactured using the carbon-glass composite carbonized sheet member manufactured by the manufacturing method of the present invention,

FIG. 7 is a diagram illustrating a water purification filter manufactured using the carbon-glass composite carbonized sheet member manufactured by the manufacturing method of the present invention.

[Explanation of symbols]

1 glass fiber substrate, 2 wood flour, 3 mixture of wood flour and binder, 5 electric furnace, 6 charcoal,
7 glass, 8 carbon-glass composite carbonized sheet member, 41 acoustic panel, 45 speaker cone, 47 cleaning filter.

Continuation of the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B32B 17/02 D06M 11/76 D06M 11/79 H04R 7/02

Claims (4)

(57) [Claims] 1. A carbon-glass composite carbonized sheet member characterized in that charcoal and glass are formed in a matrix in a sheet made of a glass fiber base material. 2. After adhering wood flour to the glass fiber substrate,
A method for producing a carbon-glass composite carbonized sheet member, characterized in that charcoal and glass are formed in a matrix in a sheet made of a glass fiber substrate by performing firing and carbonizing treatment. 3. The carbon powder according to claim 2, wherein said wood flour comprises a mixture of wood flour and a binder.
A method for producing a glass composite carbonized sheet member. 4. The mixing ratio of wood powder and binder in the mixture is 10: 1 to 1: 1 by weight of charcoal and binder.
4. The carbon according to claim 3, wherein the carbon-
A method for producing a glass composite carbonized sheet member.