JP3357020B2 - Charcoal molded product and method for producing 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 charcoal molded product that can be used in various fields including building materials, water treatment materials, pet supplies, health-related appliances and the like, and a method for producing the same.

[0002]

2. Description of the Related Art It has been reported in several patent publications that charcoal boards made from bamboo charcoal while keeping the inherent pores in an active state are excellent in dehumidification, deodorization, sound absorption and electromagnetic wave shielding properties. It is disclosed and described in publications and is well known. However, these known charcoal boards are:
With only one exception, the use of petrochemicals in the binder has a high risk of producing formaldehyde odors or releasing substances that cause atopic dermatitis.

[0003] Japanese Patent Application Laid-Open No. 7-150645 discloses a mixed material comprising bamboo charcoal granules or dried timber bamboo pellets having an average particle size of 2 to 7 mm, or 60 to 90% by weight of dry timber bamboo fiber and the balance cement as a plate. Alternatively, a charcoal board that is pressure-formed in a block shape is disclosed. Although this charcoal board is effective for underfloor humidifiers used on the ground under the floor of a house and for deodorizing plates installed in a treatment tank for livestock manure, it is difficult to reduce the weight and thickness. There's a problem.
Although this patent publication discloses a mixture of a synthetic resin binder, the use of cement is an essential requirement, and this charcoal board does not solve the problem of weight reduction and thinning.

Japanese Patent Application Laid-Open No. 7-150743 discloses a building member containing charcoal powder, and this building member is also formed using a synthetic resin binder. That is, this architectural member is composed of a charcoal powder layer including or supplementing a reinforcing member, and a breathable sheet member including the charcoal powder layer and the reinforcing member. The charcoal powder layer includes, for example, an aqueous adhesive prepared by enclosing a charcoal powder with a reinforcing member of a lath net having a zinc-plated surface, and dissolving a water-soluble synthetic resin polyvinyl alcohol in water having a predetermined concentration. It is a board-like member in which the added mixture is solidified or semi-solidified by a pressure machine.

[0005] However, since this building member has the three essential components of the charcoal powder, the reinforcing member, and the air-permeable sheet member, a step of disposing the reinforcing member in the middle of the charcoal powder layer, It is manufactured through a process of adhering to a solidified or semi-solidified board-like charcoal powder layer, but there is a problem that quality control is extremely difficult in each process.

A serious problem common to the charcoal board disclosed in Japanese Patent Application Laid-Open No. Hei 7-150645 and the building member containing charcoal powder disclosed in Japanese Patent Application Laid-Open No. Hei 7-150743 is as follows.
The use of a synthetic resin binder has a high risk of generating formaldehyde odor and releasing a substance that causes atopic dermatitis.

[0007] The only exception mentioned above is Japanese Patent Application Laid-Open No. 9-30280.
No. 3 discloses this. This is a 250mm × 250mm × manufactured using natural fiber fibrillation as a binder
It is a charcoal board having a strength of about 20 mm or more, which is at least as strong as a gypsum board. The natural fiber fibrillation material used as a binder is a crusher composed of a cellulose-based natural fiber alone or a mixture of a cellulose-based natural fiber and a collagen-based natural fiber, using a two-stage non-porous grindstone. By sub-micron diameter. However, an inexpensive charcoal board using a binder using this natural product as a starting material is unfortunately not yet commercialized.

[0008]

The first problem to be solved
An object of the present invention is to provide a charcoal molded product using a natural product as a binder. A second problem to be solved is to provide a method for mass-producing a charcoal molded product using a natural product as a binder at low cost.

[0009]

Means for Solving the Problems A charcoal molded product which solves the above first problem was produced using glucomannan as a binder. That is, a charcoal molded product which solves the first problem is formed by mixing a charcoal molding material obtained by adding water to powdery or granular charcoal or charcoal obtained by mixing them and a small amount of glucomannan powder and kneading the mixture into a predetermined mold. And press-formed. The mold may be a wooden mold or a plaster mold as long as it is suitable for pressure molding.

[0010] A method for producing a charcoal molded product which solves the above-mentioned second problem is to knead a powdery or granular charcoal or a charcoal obtained by mixing them with a small amount of glucomannan powder and adding water to the charcoal. A kneading process, a charcoal molding material obtained by the kneading process, a pressure forming step of pouring the charcoal molding material into a mold and pressing, and a drying and solidifying step of drying and solidifying the semi-finished product obtained by the pressing molding process. And the process.

[0011] The amount of the glucomannan powder is about 1.5 to 6.0% by weight based on the charcoal. In addition, the glucomannan powder used had been subjected to a water absorption / swelling step of previously dispersing well in an appropriate amount of water and absorbing / swelling to some extent.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of a method for manufacturing a charcoal molded product according to the present invention is shown in FIG.
It comprises three steps: a kneading step S1, a pressure forming step S2, and a drying / solidifying step S3. The kneading step S1 is a step of adding water 13 to the powdery or granular charcoal 11 and a small amount of glucomannan powder 12, and kneading them sufficiently with a stirrer.

The amount of the glucomannan powder 12 is about 1.5 to 6.0% by weight with respect to the powdery or granular charcoal 11. However, an amount exceeding 6.0% by weight, for example, 10.
It may be 0% by weight.

The water 13 added for kneading is
It is about 45 to 90% by weight with respect to the powdery or granular charcoal 11.

The pressure forming step S2 includes a kneading step S1
This is a step of pouring the charcoal molding material 14 sufficiently kneaded through the mold into a mold, and press-molding the mold into which the charcoal molding material 14 has been poured by a pressure molding machine.

The drying and solidifying step S3 includes a pressure forming step S2
This is a step of drying and solidifying the charcoal semi-finished product 15 formed under pressure through the mold and taken out of the mold indoors or outdoors (sunshine).

The second aspect of the method for producing a charcoal molded product according to the present invention is as follows.
As shown in FIG. 2, the embodiment includes four steps: a kneading step S1, a pressure forming step S2, a drying / solidifying step S3, and a water absorbing / swelling step S4. The water absorption / swelling step S4 is a step performed prior to the kneading step S1, and is a step in which the glucomannan powder 12 is well dispersed in the water 13 to absorb and swell to some extent. This water absorption
The water 13 added to the glucomannan powder 12 in the swelling step S4 is between 45 and 45
The total amount or a part of water of about 90% by weight. Water absorption
The remaining water 13 not used in the swelling step S4 is used in the kneading step S1. The water absorption / swelling step S4 is provided so that the powdery or granular charcoal 11 and the glucomannan 12 are more uniformly mixed in the kneading step S1.

The charcoal used in the production of the nine embodiments described below is bamboo charcoal produced by the carbonization method. That is,
It is a bamboo charcoal that grows naturally in large quantities, cuts bamboos such as Moso bamboo and madake, which are available in large quantities at a low price, cuts the bamboo into appropriate lengths, and carbonizes them by carbonizing in an iron furnace. The carbonization temperature in this case was 300 to 500 ° C. In addition, the bamboo material of the raw material cut | disconnected about 1 m, and two kinds of the strip-shaped split bamboo of about 5 cm in length were prepared.

Using pulverized coal, granular charcoal, and long-coal charcoal, several charcoal boards were manufactured. Powdered bamboo charcoal powdered bamboo charcoal with a particle size of about 2 mm, which is obtained by finely crushing and sieving bamboo charcoal with a crusher,
Granulated charcoal has a reduced degree of pulverization and has a sieved particle size of 10-20.
Granular bamboo charcoal of about mm and long grain charcoal are thin pieces of bamboo charcoal obtained by carbonizing strip-shaped split bamboo of about 5 cm by the above-described method.

In order to manufacture a charcoal board using pulverized coal, granular coal, or long-charcoal, a stirrer, a hydraulic hot press machine, a mold having a diameter of 43 cm square and a depth of 5 cm, and an iron plate with a steam vent hole are used. Using.

A charcoal board as a charcoal molded product according to the present invention was manufactured through a kneading step S1, a pressure forming step S2, and a drying / solidifying step S3, as shown in the flowchart of FIG. 1 or FIG. That is, first, powdery or granular bamboo charcoal 11 and glucomannan of about 1.5 to 6.0% by weight with respect to bamboo charcoal 11 were added with water 13 and sufficiently kneaded with a stirrer. Water 1 added for kneading
In No. 3, about 45 to 90% by weight of bamboo charcoal 11 was sufficient. As shown in the flow chart of FIG. 2, this glucomannan powder 12 has undergone a water absorption / swelling step S4, that is, a swelled glucomannan 17 that has been well dispersed in a suitable amount of water in advance and has absorbed and swelled to some extent. Used.
The sufficiently kneaded charcoal molding material 14 was poured into a mold, and covered with an iron plate having a steam vent hole. Charcoal molding material 14
Was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine, and pressure-molded at a predetermined temperature for a predetermined time. After a lapse of a predetermined time, the hot press was released, and the pressure-formed half-finished charcoal 15 was taken out of the hot press. Finally, the semi-finished charcoal product 15 was dried and solidified indoors or outdoors (sunshine) to complete a charcoal molded charcoal board 16.

From a plurality of products described below, it has been found that glucomannan powder, which is a natural product, is effective as a binder for producing a charcoal molded product using powdery or granular bamboo charcoal. It has been found that a small amount of glucomannan powder mixed as a binder with powdery or granular bamboo charcoal is sufficient, specifically, about 1.5 to 6.0% by weight of bamboo charcoal is sufficient. .

Further, in order to mix a small amount of glucomannan with the powdery or granular bamboo charcoal as a binder, water was added to these materials and kneaded sufficiently with a stirrer. Through this kneading step, a charcoal molding material was obtained in which bamboo charcoal and glucomannan were uniformly mixed and could be efficiently poured into a mold in a required amount. The amount of water to be added to the powdery or granular bamboo charcoal and a small amount of glucomannan is a charcoal molding material in a kneaded state with a hardness that allows them to be evenly mixed and efficiently poured into the mold in the required amount. Anything that can be provided can be used.

Furthermore, a predetermined temperature and a predetermined time are required for pressure molding with a hot press machine. These predetermined temperature and predetermined time are necessary for at least calcium and other alkali elements in the charcoal of the charcoal molding material to react with glucomannan and solidify. The predetermined temperature is 1
It turned out that about 00 ° C. is sufficient. However, it has been found that the predetermined time is not constant and varies depending on the size of the charcoal molded product to be produced and other production conditions. The pressure applied by the hot press machine is not constant because it is almost released at an extremely early stage due to the presence of air, the collapse of charcoal, and the like. In short, the optimal initial pressure will be selected according to the size of the charcoal molded product to be produced and other production conditions.

The plurality of products described below are charcoal boards having a finished thickness of 10 to 38 mm, a size of 43 cm square, and a volume specific gravity of 0.27 to 0.54 g / cm ³ .
However, the size of the charcoal board can be arbitrarily selected according to the application. In addition, a charcoal board having a curved surface can be manufactured by forming the mold into a desired size and shape.

By the way, the finish thickness of 10 to 38 mm 4
3cm square size, its volume specific gravity is 0.27 ~ 0.5
The strength of the charcoal board of the below-described product of 4 g / cm ³ was confirmed to have a bending strength comparable to that of a styrene foam board of the same size. That is, after sufficiently drying each board and leaving it in a room for a certain period, three test pieces having a width of about 40 mm and a length of about 200 mm are cut out from each board, and three points (central concentration) are obtained.
As a result of the bending strength test performed by the weighting method, the average of the bending stress degrees of the three test pieces was 0.91 MPa for the third embodiment,
1.36MPa for the fourth embodiment, 0.78M for the fifth embodiment
Pa, the seventh product was 0.21 MPa, and the eighth product was 0.36 MPa. Although it depends on the expansion ratio, the bending strength of the styrofoam board is 0.2 to 1.0 MPa (2
-10 kgf / cm ² ), it can be seen that each of the examples has a bending strength that can be compared with that of the Styrofoam board. Therefore, the charcoal board according to the present invention has sufficient strength that it is not broken even when used under a tatami or carpet. It was also recognized that the charcoal board according to the present invention hardly differs from the bamboo charcoal itself in gas adsorption capacity. This is because the amount of glucomannan powder added as a binder to bamboo charcoal is as small as several percent or less by weight.

The binder may not be purified glucomannan powder, but may be, for example, a natural konjac potato sliced to an appropriate thickness, sun-dried and ground. This is effective in reducing raw material costs.

[0028]

EXAMPLE 1 First example 1 kg of pulverized coal and 15 g of glucomannan powder in 450 ml of water
And kneaded with a stirrer. A sufficiently kneaded charcoal molding material was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 100 ° C. for 1 hour. The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the first product is 43mm with a thickness of 10mm
A board with an m-square size and a volume specific gravity of 0.50 g / cm
It was ³ .

Second embodiment 1 kg of pulverized coal and 25 g of glucomannan powder in 750 ml of water
And kneaded with a stirrer. The charcoal molding material sufficiently kneaded in this manner is poured into a mold, and the mold covered with an iron plate having a steam vent hole is placed in a hot press machine, and is pressed at 100 ° C. for 1 hour. did. The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the second embodiment was a board having a size of 43 cm square and a thickness of 10 mm, and the volume specific gravity was 0.50 g / cm ³ .

Third Example Product 1 kg of pulverized coal and 30 g of glucomannan powder in 600 ml of water
And kneaded with a stirrer. A sufficiently kneaded charcoal molding material was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 100 ° C. for 1 hour. The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the third embodiment is 43 mm with a thickness of 10 mm.
A board with an m-square size and a specific gravity of 0.54 g / cm
It was ³ .

Fourth embodiment 1 kg of long-grain charcoal and 45 g of glucomannan powder were mixed with 900 m of water.
and kneaded with a stirrer. A sufficiently kneaded charcoal molding material was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 100 ° C. for 1 hour. The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the fourth embodiment is 43mm with a thickness of 15mm.
A board with a size of cm square, volume specific gravity 0.38g / c
It was m ^3.

Fifth embodiment 1 kg of granular charcoal and 45 g of glucomannan powder are mixed with 900 ml of water.
And kneaded with a stirrer. A sufficiently kneaded charcoal molding material was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 100 ° C. for 1 hour. The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the fifth embodiment is 4 with a thickness of 22.5 mm.
3cm square board with specific gravity of 0.27g /
cm ³ .

Sixth Embodiment 1200 ml of water was added to 2 kg of mixed charcoal obtained by mixing powdered charcoal and granular charcoal in equal amounts and 60 g of glucomannan powder, and kneaded with a stirrer. A sufficiently kneaded charcoal molding material was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 100 ° C. for 1 hour.
The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the sixth embodiment was a board having a thickness of 38 mm and a size of 43 cm square, and the volume specific gravity was 0.29 g / cm ³ .

Seventh Embodiment 1200 ml of water was added to 2 kg of mixed charcoal obtained by mixing powdered charcoal and granular charcoal in equal amounts and 60 g of glucomannan powder, and kneaded with a stirrer. A sufficiently kneaded charcoal molding material was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 105 ° C. for 1 hour.
The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the seventh embodiment was a board having a thickness of 29 mm and a size of 43 cm square, and the volume specific gravity was 0.40 g / cm ³ .

Eighth Embodiment [0035] To 2.5 kg of mixed charcoal obtained by mixing pulverized charcoal and granular charcoal in equal amounts and 75 g of glucomannan powder, 1500 ml of water was added and kneaded with a stirrer. A sufficiently kneaded charcoal molding material was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 105 ° C. for 1 hour. The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the eighth embodiment was a board having a thickness of 30 mm and a size of 43 cm square, and the volume specific gravity was 0.46 g / cm ³ .

Ninth Embodiment 1.5 kg of granular charcoal and 90 g of glucomannan powder were mixed with 900 parts of water.
ml was added and kneaded with a stirrer. A sufficiently kneaded charcoal molding material is poured, and a mold covered with an iron plate having a steam vent hole is placed in a hot press machine.
Press molding was performed over time. The charcoal semi-processed product taken out of the hot press was dried and solidified in the room to complete a charcoal board. The charcoal board of the ninth embodiment has a thickness of 18 mm 4
A board with a size of 3 cm square with a specific gravity of 0.48 g /
cm ³ .

First comparative product 1 kg of pulverized coal and 15 g of glucomannan powder in 450 ml of water
And kneaded with a stirrer. A sufficiently kneaded charcoal molding material was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 100 ° C. for 40 minutes. However, the one taken out of the hot press had a thickness of about 25 mm, but was not formed into a board.

Second Comparative Product 200 ml of ethanol was added to 0.5 kg of wood flour, 0.5 kg of granular charcoal and 220 g of resorcinol resin adhesive, and kneaded with a stirrer. A sufficiently kneaded molding material mixed with charcoal was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine and pressed at 105 ° C. for 30 minutes. The charcoal-mixed semi-processed product removed from the hot press was dried and solidified in a room to complete a charcoal-mixed board. The charcoal-mixed board of the second comparative product is 21.5 mm thick
43cm square board with a specific gravity of 0.44
g / cm ³ , but a formaldehyde odor was generated.

Third comparative product 0.75 kg of wood flour, 0.75 kg of granular charcoal and 660 g of resorcinol resin adhesive were kneaded with a stirrer. A sufficiently kneaded molding material mixed with charcoal was poured, and a mold covered with an iron plate having a steam vent hole was placed in a hot press machine, and pressed at 105 ° C. for 16 hours. Dry the charcoal-mixed semi-processed product taken out of the hot press machine indoors.
Solidified to complete the bamboo charcoal-mixed board. The charcoal-mixed board of the third comparative product was a board having a size of 43 cm square having a thickness of 21 mm and a volume specific gravity of 0.48 g / cm ³ , but a formaldehyde odor was generated.

As described above, the charcoal molded product of the board using bamboo charcoal has been described in detail with reference to a plurality of practical products, but the present invention is not limited to this. Therefore, the charcoal according to the present invention includes charcoal made from cedar, pine, cypress, oak, kunagi and other trees, that is, charcoal having a higher calcium content than bamboo charcoal. In addition, the charcoal molded product according to the present invention includes rod-shaped, cylindrical, and other various shaped products according to applications.

[0041]

According to the present invention, it is possible to provide a charcoal molded product using a binder of a natural material which can be obtained inexpensively and in large quantities. That is, in the present invention, glucomannan serving as a binder uses natural konjac potato as a raw material, and its use amount is as small as about several percent of charcoal.

Since the charcoal molded product according to the present invention uses only natural materials as raw materials, it hardly pollutes the environment in all steps of its production, use and disposal. Also,
The charcoal molded product according to the present invention has a dehumidifying property, a deodorizing property, a sound absorbing property,
Because it is molded into a shape according to the application while retaining electromagnetic wave shielding properties, it is used for building materials for healthy houses, pet supplies,
It has become possible to provide cheap charcoal molded products that are optimal as water treatment materials.

Further, the method for manufacturing a charcoal molded product according to the present invention does not use a newly designed and manufactured device or equipment having a special structure, so that the equipment investment for industrial production is enormous. Therefore, the production cost can be kept low without impairing the merits of raw materials which can be obtained cheaply and in large quantities. For this reason, it has become possible to produce inexpensively large quantities of charcoal molded products using charcoal and a natural product binder.

[Brief description of the drawings]

FIG. 1 is a flowchart showing a first embodiment of a method for manufacturing a charcoal molded product according to the present invention.

FIG. 2 is a flowchart showing a second embodiment of the method for producing a charcoal molded product according to the present invention.

[Explanation of symbols]

 Reference Signs List 11 powdery or granular charcoal 12 glucomannan powder 13 water 14 charcoal molding material 15 charcoal semi-finished product 16 charcoal molded product 17 swollen glucomannan S1 kneading process S2 pressure molding process S3 drying / solidification process S4 water absorption / swelling process

──────────────────────────────────────────────────続 き Continuing on the front page (72) Kazuhiko Matsunaga, Inventor Kagoshima Pref., 1445-1 Oda, Hayato-cho, Aira-gun Kagoshima Pref. References JP-A-11-131633 (JP, A) JP-A-10-168348 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 43/00-43/58 E04C 2/10-2/24

Claims (4)

(57) [Claims] 1. A charcoal molded product produced by press-molding a charcoal molding material obtained by adding water to powdery or granular charcoal or charcoal obtained by mixing them and a small amount of glucomannan powder and kneading them. 2. A kneading step in which powdery or granular charcoal or a charcoal obtained by mixing them and a small amount of glucomannan powder are kneaded by adding water, and the charcoal molding material obtained in the kneading step is poured into a mold. A method for producing a molded charcoal product, comprising: a pressure molding step of performing pressure molding; and a drying and solidifying step of drying and solidifying a charcoal semi-finished product obtained by the pressure molding step. 3. The method according to claim 2, wherein the amount of the glucomannan powder is about 1.5 to 6.0% by weight based on the weight of the charcoal. 4. The method for producing a charcoal molded product according to claim 2, wherein the glucomannan powder has been subjected to a water absorption and swelling step in which the glucomannan powder is well dispersed in an appropriate amount of water in advance and absorbs and swells to a certain extent. Method.