JP4415125B2 - Synthetic board with woven fabric or nonwoven fabric and method for producing the same - Google Patents

Description

The present invention relates to a synthetic board with a woven fabric or a nonwoven fabric and a method for producing the same .

Conventionally, a synthetic board used for an interior member or a building member of a vehicle has been molded by mixing a wood chip, a fiber material, or the like with a phenol resin or the like as an adhesive.
However, synthetic boards molded from petroleum-derived materials generate carbon dioxide when incinerated, increasing the amount of carbon dioxide as a whole, and phenolic resins contain free phenol and formaldehyde, which adversely affects the human body. There was a fear.

Then, the technique which shape | molds a synthetic board by heat-pressing the lignocellulosic material derived from the plant which performed the steaming process and the explosion process without mixing an adhesive agent is developed (refer patent document 1).
Because this is molded only from plant-derived materials, even if carbon dioxide is emitted by incineration, the equivalent amount of emission is absorbed during plant growth, and the carbon dioxide amount changes as a whole Not so environmentally superior. In addition, there are almost no substances that affect the human body.

On the other hand, when the synthetic plate is used as an interior member or a building member of a vehicle, a woven fabric or a non-woven fabric (hereinafter also referred to as a non-woven fabric) may be bonded to the surface of the synthetic plate via an adhesive (Patent Document 2). reference).
In general, when bonding non-woven fabric or the like to a synthetic board, a chloroprene rubber solvent-type adhesive dissolved in an organic solvent such as acetone, toluene or n-hexane is applied to the synthetic board and bonded. Yes.
JP 2001-1318 A JP-A-9-39127

However, when a nonwoven fabric or the like is bonded to the synthetic plate in Patent Document 1 or Patent Document 2, an adhesive must be applied to the surface of the synthetic plate, and the nonwoven fabric or the like must be placed thereon and pressurized. This has a problem that the cost is increased due to the use of an adhesive and the addition of a pressurizing operation.
In addition, chloroprene rubber-based adhesives used for bonding are organic solvents such as acetone, toluene and n-hexane, which may adversely affect the human body when used in vehicles and houses. There was also a problem.

The present invention has been made to solve such a problem, and its purpose is as follows:
An object of the present invention is to provide a woven fabric or a synthetic plate with a nonwoven fabric that can reduce the burden on the environment and the human body, and can simplify the bonding work of a nonwoven fabric or the like, and a method for manufacturing the same.

In order to achieve the above-mentioned object, the synthetic board with woven fabric or nonwoven fabric according to claim 1 is molded from a preform produced by heating and pressing a lignocellulosic material subjected to either steaming or explosion treatment. a synthetic board that is, placed on the preform, in Rukoto heated and pressed at a lower pressure than the pressure, attached to the synthetic board by a resin component in the lignocellulosic material to the molding both of the synthetic board It is characterized in that it comprises a intertwined Ru woven or nonwoven fabric.
Moreover, in the method for producing a woven fabric or a nonwoven fabric-attached synthetic board according to claim 2, a preform is produced by heating and pressurizing a lignocellulosic material subjected to either steaming or explosion treatment, and the pressurization is performed. After the release, the nonwoven fabric is placed on the preform, and is molded by pressing at a lower pressure than the preform production.
Thus, by performing steaming / explosion treatment, hemicellulose and lignin contained in the woody and vegetative materials are decomposed to produce resin components, and a woven fabric or a nonwoven fabric is bonded together with the formation of the synthetic plate.

Further, the lignocellulosic material is subjected to steaming / explosion treatment, so that it can be molded from a softened material containing moisture.
Furthermore, since the steaming / explosion treatment is performed at high temperature and high pressure, insects, molds, bacteria, etc. contained in the lignocellulosic material are killed and sterilized.

According to the synthetic board with a woven or non-woven fabric according to claims 1 and 2 of the present invention using the above means and the method for producing the same, the resin component produced by the steaming / explosion treatment serves as an adhesive in the molding of the synthetic board And since it plays a role as an adhesive agent to a nonwoven fabric etc., shaping | molding of a synthetic plate and bonding of a nonwoven fabric etc. can be performed in the same process, and the bonding operation | work of a nonwoven fabric etc. can be simplified.
In addition, in the heat and pressure molding, as a first step, a preform is produced by pressurizing the synthetic plate at a high pressure, the pressure is released in the middle, the temperature is changed, and then the woven or non-woven fabric is formed on the synthetic plate. By placing on the surface and pressurizing at a low pressure, the woven fabric or the non-woven fabric can be prevented from being crushed and molded with good aesthetics.
Further, a three-dimensional shape such as deep drawing can be formed by molding from a material softened by containing moisture.

Furthermore, antiseptic and durability can be improved by the insecticidal and bactericidal action of the steaming / explosion treatment.
Furthermore, since all can be molded from plant-derived materials, an increase in carbon dioxide due to incineration can be suppressed. In addition, since harmful substances can be reduced, the influence on the human body can be reduced.

  Thereby, while reducing the burden on an environment or a human body, the bonding operation | work of a nonwoven fabric etc. can be simplified.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Referring to FIG. 1, a perspective sectional view of a synthetic board with a woven fabric or a nonwoven fabric according to the present invention is shown.
As shown in FIG. 1, the synthetic plate 1 with nonwoven fabric has a nonwoven fabric 4 bonded on a synthetic plate 2.

The synthetic plate 2 is formed of a lignocellulosic material that has been subjected to either steaming or explosion treatment.
As the lignocellulosic material, for example, fibrous or powdery materials derived from woody or vegetative plants such as wood, bamboo, kenaf and the like are used. When such a lignocellulosic material is subjected to steaming and explosion treatment, the hemicellulose and lignin contained in the woody and vegetative materials are decomposed and a resin component is produced, so that the adhesive force is improved.
Furthermore, since the steaming / explosion treatment is performed at high temperature and high pressure, insects, molds and bacteria contained in the lignocellulosic material are killed and sterilized to improve antiseptic and durability.

  And the molding of the synthetic board 2 is performed by filling the mold with the lignocellulosic material that has been steamed / explosively treated, placing the nonwoven fabric 4 on it, and heating and pressurizing the synthetic board 2 and bonding the nonwoven fabric 4 simultaneously. Do. That is, the resin component produced by performing the steaming / explosion treatment acts as an adhesive for the lignocellulosic material and also serves as an adhesive for the nonwoven fabric 4.

In addition, in the heat and pressure molding, the preform 2a is produced by pressurizing the synthetic plate 2 at a high pressure as the first step, the pressure is released halfway, the temperature is changed, and then the nonwoven fabric 4 is made into the synthetic plate 2 The nonwoven fabric 4 can be prevented from being crushed by being placed on and pressed at a low pressure, and can be molded with good aesthetics.
Here, an example of the concrete shaping | molding method of the woven fabric which concerns on this invention, or the synthetic board with a nonwoven fabric is given.
Referring to FIG. 2, there is shown a perspective view showing the construction of a synthetic board with a woven fabric or nonwoven fabric according to the present invention, and with reference to FIG. 3, the synthetic board with a woven fabric or nonwoven fabric according to the present invention is shown. The perspective view which shows the structure at the time of heating-pressing is shown. Hereinafter, a description will be given with reference to FIGS.

As shown in FIG. 2, a Teflon (R) sheet 8 reinforced with glass fiber is laid on a stainless steel plate 6 for producing a preform 2a of the synthetic plate 2, and an L-shaped frame member 10a is formed thereon. A square mold 10 is formed by combining two 10b.
The mold 10 is uniformly filled with the lignocellulosic material that has been steamed and crushed.
Then, an upper mold which is a drop lid of the same size as the inner periphery of the mold 10 and a piece of wood for height adjustment (both not shown) are disposed.

These are installed in the hydraulic press device together with the mold 10 and pressed for a predetermined time to produce the preform 2a. The pressure at this time should just be a grade which the preform 2a can hold | maintain a shape until this pressurization.
The produced preform 2a is taken out together with the mold 10 from the hydraulic press device, and the L-shaped frame members 10a and 10b and the upper mold are removed.

And as shown in FIG. 3, the nonwoven fabric 4 is arrange | positioned on the preform 2a on the stainless steel plate 6, and the Teflon (R) sheet | seat 12 and the stainless steel plate 14 are arrange | positioned in order further upwards from the nonwoven fabric 4. FIG. Further, square-shaped stainless steel spacers 16 are arranged in parallel to the preform 2a with a slight gap on both sides of the preform 2a.
The preform 2a and the nonwoven fabric 4 sandwiched between the stainless plates 6 and 14 are placed in another hydraulic press apparatus in which the upper mold and the lower mold are heated in advance, and are subjected to pressure molding.

Thus, in the synthetic board with a woven fabric or nonwoven fabric according to the present invention, the synthetic board 2 is formed from a lignocellulosic material subjected to steaming / explosion treatment, and the bonding of the nonwoven fabric 4 is also produced by steaming / explosion treatment. Since the resin component to be used is used as an adhesive, the molding of the synthetic plate 2 and the bonding of the nonwoven fabric 4 can be performed in the same process.
In addition, the use of plant-derived lignocellulosic materials without the use of petroleum-derived materials or adhesives, and the combination of herboard molding and non-woven fabric prevents the increase in the amount of carbon dioxide due to incineration, etc. In addition, the burden on the human body can be reduced.

  Therefore, it is possible to reduce the burden on the environment and the human body and simplify the bonding work of the nonwoven fabric or the like.

Example 1
Bamboo fiber (200 mm length) that had been subjected to explosion treatment (explosion conditions: pressure 9 atm, temperature 180 ° C., time 20 minutes) was used as the lignocellulosic material.
160 g of the bamboo fibers were filled in a mold as in the above example, and a pressure of 0.77 MPa was applied for 5 minutes by a hydraulic press device to produce a preform 2a.

  Then, a PET non-woven fabric is placed on the preform 2a, spacers having a thickness of 4 mm are arranged on both sides, and the upper mold and the lower mold are arranged in another hydraulic press apparatus heated to 180 ° C. in advance. A synthetic plate with a woven or non-woven fabric was molded by heating and pressing 106 kN (for a 19 × 19 cm preform) for 10 minutes.

Example 2
Bamboo fiber (200 mm length) that had been subjected to explosion treatment (explosion conditions: pressure 9 atm, temperature 180 ° C., time 20 minutes) was used as the lignocellulosic material.
160 g of the bamboo fibers were filled in a mold as in the above example, and a pressure of 0.77 MPa was applied for 5 minutes by a hydraulic press device to produce a preform 2a.
Then, a PET non-woven fabric is placed on the preform 2a, spacers having a thickness of 6 mm are arranged on both sides, and the upper mold and the lower mold are arranged in another hydraulic press apparatus heated to 160 ° C. in advance. A synthetic plate with a woven fabric or a nonwoven fabric was molded by heating and pressurizing at 26 kN (for a 19 × 19 cm preform) for 10 minutes.

Example 3
As the lignocellulosic material, beech wood flour (2 mm mesh pass material) that had been steamed (steaming conditions: temperature 200 ° C., time 20 minutes) was used.
As shown in the above example, 155 g of the beech wood powder was filled into a mold, and 0.77 MPa was applied for 5 minutes by a hydraulic press device to produce a preform 2a.
Then, a PET nonwoven fabric is placed on the preform 2a, spacers having a thickness of 4 mm are disposed on both sides, and the upper mold and the lower mold are disposed in another hydraulic press apparatus that is heated to 180 ° C. in advance. A synthetic plate with a woven or non-woven fabric was molded by heating and pressing 106 kN (for a 19 × 19 cm preform) for 10 minutes.

Comparative Example A chloroprene rubber-based solvent-type adhesive was applied to a synthetic plate formed by a known means (a synthetic plate formed by mixing a wood chip with a phenol resin).
And the PET nonwoven fabric was mounted on the surface which apply | coated the adhesive agent, and it bonded by pressurizing at 0.1 Mpa for 24 hours.
The woven fabric or non-woven fabric synthetic plate formed as in Examples 1 to 3 and Comparative Example above was cut into physical property measurement test pieces (for example, bending test pieces: 148 mm × 50 mm × 3.65 mm, water absorption rate test pieces: 50 mm). × 50 mm × 3.65 mm), and each test of adhesiveness to the nonwoven fabric, analysis of TVOC and aldehyde, three-dimensional formability, water absorption, and bending strength was performed. The results are shown in FIG.

As shown in FIG. 4, the adhesion test with the nonwoven fabric was a test for peeling the bonded nonwoven fabric. As a result, the nonwoven fabric was broken in Examples 1 to 3, and the synthetic plate was broken in the comparative example. That is, it can be said that Examples 1 to 3 have sufficient strength of the synthetic plate while having sufficient adhesion between the synthetic plate and the nonwoven fabric.
It can be seen that Examples 1 to 3 have lower TVOC and aldehyde than the comparative examples and have less influence on the human body.

Here, the numerical values of TVOC, formaldehyde, and acetaldehyde shown in FIG. 4 are as follows. One test piece having dimensions of 19 cm in length × 19 cm in width × 0.4 to 0.6 cm in thickness is placed in 15 liters of pure air at an ambient temperature of 65 ° C. The amount generated when left for 2 hours is calculated per cubic meter.
Examples 1 to 3 have good three-dimensional formability, whereas the comparative examples are poor. From this, it can be said that Examples 1 to 3 can be shaped freely. Further, Examples 1 to 3 have a water absorption rate equivalent to that of the comparative example. Further, it can be seen that Examples 1 to 3 ensure the same bending strength as that of the synthetic plate mixed with the adhesive as in the comparative example even without the adhesive.

  The heating temperature at the time of heating and pressing is preferably 160 ° C. or higher as shown in the above examples. Although a specific comparative example is omitted, it has been found that at about 150 ° C., the resin component cannot sufficiently exhibit adhesiveness and the strength of the synthetic plate cannot be ensured. That is, if heat-press molding at 160 ° C. or higher is performed, the resin component in the lignocellulosic material is sufficiently generated, and the strength of the synthetic plate and the bonding strength of the woven or non-woven fabric can be ensured.

From the above test results, Examples 1 to 3 according to the present invention are suitable for use in a vehicle or the like.
Although the description about embodiment of the woven fabric which concerns on this invention or the synthetic board with a nonwoven fabric is finished above, embodiment is not restricted to the said embodiment.
For example, although the nonwoven fabric is bonded to the synthetic board 2 in the said embodiment, a woven fabric may be sufficient.

  Further, in the above examples, an example in which a crushed or steamed material is applied as a lignocellulosic material is shown, but the present invention is not limited to this, and as a lignocellulosic material, for example, a common bamboo fiber or Kenaf or hemp may be applied.

It is a perspective view of the synthetic board with a woven fabric or a nonwoven fabric which concerns on this invention. It is a perspective view which shows the structure at the time of preform preparation of the synthetic board of the woven fabric which concerns on this invention, or a synthetic board with a nonwoven fabric. It is a perspective view which shows the structure at the time of the heating and pressurization of the woven fabric which concerns on this invention, or the synthetic board with a nonwoven fabric. It is the table | surface which showed the test result of Example 1 thru | or 3 of the woven fabric which concerns on this invention, or a synthetic board with a nonwoven fabric, and a comparative example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Synthetic board with nonwoven fabric 2 Synthetic board 2a Preform 4 Nonwoven fabric 6, 14 Stainless steel plate 8, 12 Teflon (R) sheet 10 Mold 10a Frame member 16 Spacer

Claims (2)

A synthetic plate formed from a preform produced by heating and pressurizing a lignocellulosic material subjected to either steaming or explosion treatment;
Wherein mounted on the preform, the at Rukoto heat and pressure at a lower pressure than the pressure, the composite plate formed both in the lignocellulosic woven fabric by the resin component in the material Ru bonded to the composite plate or nonwoven and,
A synthetic board with a woven fabric or a nonwoven fabric, comprising: A preform is prepared by heating and pressurizing lignocellulosic material that has been subjected to either steaming or blasting treatment. After releasing the pressurization, a nonwoven fabric is placed on the preform. A method for producing a synthetic plate with a woven fabric or a nonwoven fabric, wherein the molding is performed by pressing at a low pressure.

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