JP4732844B2 - Method for producing fired molded body, method for producing fired body, and fired body - Google Patents

Description

  The present invention relates to a method for producing a fired molded body for firing to form a fired body, a method for producing the fired body, and a fired body.

  Conventionally, ceramic fired bodies have been manufactured from finely divided inorganic materials. When producing a fired body without adding anything to the finely divided inorganic material, the finely divided inorganic material is directly press-molded to form a fired molded body, and the fired molded body is fired at 800 to 2000 ° C. . Also, a finely divided inorganic material and water are put into a predetermined kneading extruder and mixed to make the material clay, and the material made into a clay is extruded from a predetermined die and formed into the shape of a fired compact. And the molded object for baking obtained is baked at 800-2000 degreeC. Here, in order to extrude the clay-like material, the weight ratio of water in the material is set higher than the weight ratio of the finely divided inorganic material.

Further, in the technique described in Patent Document 1, an inorganic filler having a particle size in the range of about 0.01 microns to about 1000 microns is surface-treated using an organosilane treating agent SiX ₁ X ₂ X ₃ X _4. After that, it is described that the filler and the organic matrix resin for bonding are mixed to obtain an injection moldable composition suitable for the shape of the ceramic substrate.
Japanese Patent Laid-Open No. 8-252813

When producing a fired body without adding anything to the finely divided inorganic material, the fired molded body may collapse during or before firing after the fired molded body is formed. The shape retention was not sufficient. Further, since the fine inorganic material is press-molded, it is necessary to press-mold each batch, the running cost is high, and it is not suitable for mass production of a fired compact.
When water is added to a finely divided inorganic material to form a molded body for firing by extrusion molding, and the fired body is manufactured, the amount of water in the material is large, so the fired molded body shrinks greatly during firing. However, a fired body having a desired shape could not be obtained, or the fired molded body collapsed during firing, and the shape retention of the fired molded body was insufficient. In addition, when the compounding quantity of the fine inorganic material in a raw material is increased, a raw material cannot be extruded from die | dye and the molded object for baking cannot be shape | molded. Moreover, since the freedom degree of the shape of the molded object for baking was small, the freedom degree of the shape of a sintered body was small.
In the technique described in Patent Document 1, it takes time to surface-treat the filler with the organosilane treatment reagent, the running cost is high, and it is unsuitable for mass production of a fired molded article. Further, the silica component of the organosilane treatment reagent is an unnecessary component for the fired body, but the silica component of the organosilane treatment reagent remains in the fired body to obtain a ceramic made of a high-purity inorganic material. I couldn't. Furthermore, when there are many compounding quantities of the filler in a raw material, it may be impossible to carry out injection molding in the shape of the molded object for baking.

  The present invention has been made in view of the above problems, and can improve the production amount of a molded body for firing per unit time, and can form a fired body by forming a fired molded body having excellent shape retention. For the purpose.

In order to achieve the above object, the invention of the method for producing a molded body for firing according to claim 1 includes at least a filler composed of a finely divided inorganic, metal, or wood-based material, and a flow equal to or less than that of the filler. And an extruding step in which the raw material containing the resin in the state is mixed by an extruding mechanism and extruded in an indefinite state, and the raw material extruded from the extruding mechanism is introduced into a predetermined introduction portion while being indefinitely shaped and baked. A molding material generation process for generating a molding material that can be molded into a shape of a molded body for firing to form a fired body by a predetermined molding mechanism from an amorphous material introduced into the introduction portion, and generation And a molding step of manufacturing a molded body for firing by molding the molded material thus formed by the molding mechanism.
That is, in the extrusion process, at least a material including a filler made of finely divided inorganic, metal, or wood-based material and a fluid in a fluid state equal to or less than the weight of the filler is mixed by an extrusion mechanism. It is pushed out in an irregular shape. In the molding material generation step, the material extruded from the extrusion mechanism is introduced into a predetermined introduction part in an indefinite shape, and a molding material is once generated from the amorphous material introduced into the introduction part. In the molding step, the generated molding material is molded by a molding mechanism to produce a fired molded body.

  In the extrusion process, the raw material is extruded in an indeterminate state, and in the forming raw material generation process, the raw material may be introduced into the introduction portion while remaining in an indefinite shape, and thus the extrusion flow rate of the raw material is not limited. Then, even if the fluid resin is a material with a small fluidity such as an equal weight or less as the filler, it becomes possible to produce a large amount of molding material per unit time, and using this molding material, It becomes possible to mass-produce the compact for firing. Here, since the fired molded body contains a resin, the fired molded body does not collapse during firing or before firing, and a fired molded body with good shape retention is obtained. Further, since the resin has a weight equal to or less than the weight of the filler, the degree of shrinkage from the fired molded body to the fired body is small. Accordingly, it is possible to improve the production amount of the molded body for firing per unit time, and to form the fired body by forming a molded body for firing excellent in shape retention.

Here, the fine particles refer to particles that are finer than powder or pellets, and include powder and fine fibers. The same applies hereinafter.
The extrusion mechanism may have various configurations and can extrude a softened material in an indefinite state by applying a general-purpose single screw kneading extruder or multi-screw kneading extruder.
Examples of the resin in a fluid state include a heat-softened thermoplastic resin and a liquid thermosetting resin.

  When the amorphous material introduced into the introduction part is molded into a pellet shape to form the molding material, in the molding step, the pellet-shaped molding material is molded by the molding mechanism, and the molded body for firing. Is manufactured. Since the molding material is pellets, the pellets can be easily molded into the shape of the molded body for firing by a molding mechanism.

  When the amorphous material introduced into the introduction part is pulverized by a predetermined pulverization mechanism and the pulverized material is formed into a pellet shape to form the molding material, the irregular material is once pulverized and pelletized. Therefore, it is possible to obtain a more uniform and high-quality fired body by making the molding material more homogeneous and making the fired molded body more homogeneous. In addition, when the pellet is used as a raw material to be molded into the shape of a molded article for firing, the pellet shape is maintained in the raw material stage, while the pellet is more easily broken in the kneading stage and dispersibility is improved, so that firing is easier. It becomes possible to shape | mold in the shape of the molded object for water. Furthermore, since the irregular shaped material is crushed, it becomes easier to enter molding holes and gaps when molding the pellet-shaped molding material, so the amount of molding material generated per unit time further increases, It becomes possible to further increase the production amount of the molded body for firing.

  When forming the molding material into a pellet shape, if the molding material is molded by extrusion molding or injection molding with a molding mechanism to produce a molding for firing, it is suitable for mass production of the molding for firing.

  When the irregular shaped material introduced into the introduction part is pulverized by a predetermined pulverization mechanism into the molding material, in the molding step, the pulverized molding material is molded by the molding mechanism. Thus, a fired molded body is produced. Since the molding material is pulverized, it is possible to obtain a more uniform and high-quality fired body by making the molding material more homogeneous and the fired compact more uniform.

  In the case where the molding material is pulverized, it is preferable to produce a fired molded body by producing the fired molded body by press molding the molding material by press molding using a molding mechanism.

When the resin is a thermoplastic resin, and the molding mechanism mixes the molding material and extrudes it from a predetermined die and molds it into the shape of the molded body for firing, the first heating that brings the thermoplastic resin into a molten state You may provide a process and the 2nd heating process of heating and softening the raw material for shaping | molding. That is, in the extrusion process, the raw material heated in the first heating process is mixed by the extrusion mechanism and extruded in an indeterminate state. In the molding step, the molding material softened in the second heating step is mixed by the molding mechanism, extruded from the die, and molded to produce the fired molded body. Thereby, when the thermoplastic resin is mixed with the filler, the molded body for firing can be mass-produced.
Here, the preferable blending ratio of the filler and the thermoplastic resin is 51 to 99% by weight (more preferably 70 to 95% by weight) of the filler, 1 to 49% by weight (more preferably 5 to 30% by weight) of the thermoplastic resin. ).

The first cooling mechanism may further include a first cooling step for cooling the molding material, and the second heating step may be configured to heat and soften the cooled molding material. Then, the molding material can be quickly solidified. Moreover, when making a shaping | molding raw material into a pellet shape, it can prevent that the shaping | molding raw material of a pellet shape adheres mutually. Furthermore, by cooling the molding material, the molding material can be easily stored as appropriate, and it becomes possible to produce a molding for firing using the stored molding material. The degree of freedom of production can be improved.
Furthermore, you may make it the structure further equipped with the 2nd cooling process which cools the molded object for baking with a 2nd cooling mechanism. Then, the fired molded body can be quickly solidified. Moreover, it can prevent that the molded object for baking adheres mutually. Furthermore, the fired compact can be easily stored by cooling the fired compact, and the fired compact can be produced using the stored fired compact. The degree of freedom can be improved.
The thermoplastic resin has an MFR (melt mass flow rate defined in JIS K7210) at a temperature of the molding material heated in the second heating step of 10 g / 10 min or more (preferably 100 g / 10 min or more). It is good also as composition which has. Then, good fluidity can be obtained when molding from the molding material into the shape of the fired molded body, and the production amount of the fired molded body per unit time can be improved.

When the resin is a liquid synthetic resin, it is not necessary to melt the resin, and it is not necessary to soften the molding material. Here, the liquid includes from a low viscosity liquid to a high viscosity liquid. The synthetic resin may be a thermoplastic resin or a thermosetting resin. The preferable blending ratio of the filler and the synthetic resin is 51 to 99% by weight (more preferably 70 to 95% by weight) of the filler and 1 to 49% by weight (more preferably 5 to 30% by weight) of the synthetic resin. If the MFR at the temperature of the molding material is 10 g / 10 min or more (preferably 100 g / 10 min or more), good fluidity can be obtained when molding from the molding material into the shape of the molded body for firing, and unit time It is possible to improve the production amount of the molded body for firing per hit.
When the synthetic resin is a thermosetting resin, it is possible to produce a fired molded body using a thermosetting resin as a raw material, which has not been possible in the past.
If the resin described above is a substance that does not contain an inorganic component or a metal component, it does not remain even after firing, so that a high-quality fired body free from unnecessary components can be obtained.

  In the extrusion step, at least the filler, the fluidized resin, and a compatibilizer having compatibility with the resin and having a hydrophilic group are mixed by the extrusion mechanism to be indefinite. It is good also as a structure extruded in this state. Then, the familiarity between the filler and the resin can be improved. A preferable blending ratio of the filler in the material to be mixed in the extrusion process is 51 to 99% by weight, and a preferable blending ratio of the resin and the compatibilizing agent in the material is 1 to 49% by weight. A preferable blending ratio of the compatibilizing agent in the material is 0.1 to 5% by weight.

  The compatibilizing agent may be a synthetic resin obtained by adding a predetermined organic acid to a raw material of a synthetic resin compatible with the resin contained in the material. Since the organic acid does not remain even after firing, a high-quality fired body can be obtained.

  In the extrusion process, a material including at least the filler, the fluidized resin, and a resin molding lubricant may be mixed by the extrusion mechanism and extruded in an indefinite state. Then, the slip between the fillers becomes good when forming from the forming material into the shape of the fired molded body. A preferable blending ratio of the filler in the material to be mixed in the extrusion process is 51 to 99% by weight, and a total blending ratio of the resin and the lubricant in the same material is 1 to 49% by weight. A preferable blending ratio of the lubricant is 0.1 to 5% by weight.

In the extrusion step, a material including at least the filler, the fluidized resin, and a fibrous material may be mixed by the extrusion mechanism and extruded in an indeterminate state. Then, the fibrous material makes the fired compact difficult to collapse. The preferred blending ratio of the filler in the material to be mixed in the extrusion step is 51 to 99% by weight, and the total preferred blending ratio of the resin and the fibrous material in the same material is 1 to 49% by weight. A preferable blending ratio of the fibrous material in the material is 0.1 to 30% by weight.
Here, the compatibilizing agent, the lubricant and the fibrous material may be a compound composed of only carbon atoms, hydrogen atoms and oxygen atoms. Furthermore, it may be a compound containing a halogen atom, a nitrogen atom, or a sulfur atom. Since such a compatibilizing agent does not remain even when fired, a high-quality fired body free from unnecessary components can be obtained.

  Further comprising a silane coupling step of obtaining a filler by reacting a fine inorganic material or metal material with a silane coupling agent, and in the extrusion step, at least the filler obtained in the silane coupling step, It is good also as a structure which mixes the raw material containing the said resin of the said fluid state with the said extrusion mechanism, and extrudes in an indefinite form. Then, the familiarity between the filler and the resin is improved. A preferable blending ratio of the filler obtained in the silane coupling step in the raw material to be mixed in the extrusion process is 51 to 99% by weight, and a preferable blending ratio of the resin in the raw material is 1 to 49% by weight. .

  In addition, the preferable mixing | blending ratio of the filler in the raw material in the case of mixing only a filler and resin in the said extrusion process is 51 to 99 weight%, and the preferable mixing | blending ratio of the resin in the same material is 1 to 49 weight%. It is.

In the molding material generating step, the amorphous material introduced into the introduction part is at least pulverized by a predetermined pulverization mechanism, and the pulverized material and the resin in the fluid state are different from each other in the physical properties. At least a second material having at least a molding material to form the molding material, and in the molding step, the molding material including at least the pulverized material and the second material is blended into the molding mechanism. It is good also as a structure which shape | molds and manufactures the molded object for baking. Since the amorphous material extruded by the extrusion mechanism is once pulverized and supplied to the molding mechanism, the molding material can be generated in a more homogenized state. Thereby, the molded object for baking can be made more homogeneous, and a high-quality molded object for baking can be mass-produced. In addition, it is possible to produce a high-quality molding material in which the physical properties of a plurality of different resins are left, and it is possible to manufacture a high-quality fired molded body in which each resin is sufficiently blended.
The second material may be a material partially made of the second resin, or may be a material made entirely of the second resin. When the mixture is generated, a mixture containing a material different from the first and second materials may be generated.
In the pulverization and mixing step, at least the first material may be pulverized, the first material alone may be pulverized to produce a mixture, or the first and second materials may be pulverized together to form a mixture. It may be produced, or each material may be pulverized separately to produce a mixture.

  By the way, the method for manufacturing a fired body according to claim 16 includes an extrusion process, a forming material generating process, a forming process, and a firing process for firing the formed fired molded body to produce a fired body. It is characterized by. Moreover, the fired body according to claim 17 uses, as an extrusion mechanism, a material including at least a filler composed of a finely divided inorganic, metal, or wood-based material, and a resin in a fluid state equal to or less than the filler. Then, the material extruded from the extrusion mechanism is introduced into a predetermined introduction portion in an indefinite shape and fired to form a fired body. A molding material that can be molded by the molding mechanism is generated from the amorphous material introduced into the introduction part, and the molded molding material is molded by the molding mechanism to form a fired compact. It is obtained by firing the formed molded body for firing. Of course, it is also possible to make the structure described in claims 2 to 15 correspond to a method for manufacturing a fired body or a fired body.

As described above, according to the invention of claim 1, a high-quality fired body can be obtained by improving the production amount of the fired molded body per unit time and forming a fired molded body having excellent shape retention. It can be manufactured.
In the invention according to the second aspect, it is possible to easily form into the shape of the fired molded body.

In the invention according to claim 3, the molding material that is formed into a pellet shape when the molding body for firing is made more homogeneous to make the firing body more uniform and is molded into the shape of the molding body for firing from the molding material is more It is possible to make it easy to collapse and to form more easily, and to further improve the production amount of the molded body for firing per unit time.
In the invention according to claim 4, in the case where the molding material is formed into a pellet shape, the production amount of the fired molded body per unit time is improved, and the fired molded body is formed by forming a fired molded body having excellent shape retention. Can be provided.

In the invention according to the fifth aspect, the fired compact can be made more homogeneous by making the fired compact more uniform.
In the invention according to claim 6, when the molding material is pulverized, the production amount of the molding for firing per unit time is improved, and the molding for firing excellent in shape retention is formed. The suitable structure which enables manufacture of a sintered body can be provided.
In the invention according to claim 7, when the thermoplastic resin is mixed with the filler, the production amount of the molded body for firing per unit time is improved, and the fired molded body having excellent shape retention is formed and fired. The suitable structure which enables manufacture of a body can be provided.
In the invention according to claim 8, there is provided a suitable configuration capable of producing a fired product by improving the production amount of the fired product per unit time and forming a fired product having excellent shape retention. be able to.

In the invention according to the ninth aspect, the familiarity between the filler and the resin becomes good, a more uniform fired molded body can be produced, and a more homogeneous fired body can be obtained.
In the invention concerning Claim 10, the molded object for baking which can obtain the high quality sintered body without an unnecessary component can be manufactured.
In the invention according to the eleventh aspect, when the material for molding is molded into the shape of the molded body for firing, since the slip between the fillers becomes good, the molding can be facilitated.
In the invention concerning Claim 12, since the molded object for baking becomes difficult to collapse, it becomes possible to manufacture the sintered object by forming the molded object for baking excellent in shape retention property.

In the invention according to the thirteenth aspect, the familiarity between the filler and the resin is improved, a more uniform fired molded body can be produced, and a more homogeneous fired body can be obtained.
In the invention according to the fourteenth aspect, it is possible to manufacture a high-quality fired molded body in which each resin is sufficiently blended, and to obtain a higher quality fired body.
In the invention according to the fifteenth aspect, since relatively small particles enter between the relatively large fillers, the fillers are held together by a large number of particles. Therefore, it is difficult to peel off the surface layer containing the fine particles from the layer containing the filler, and it is possible to mass-produce a useful fired molded body in which an important surface is densely covered with small fine particles in order to exhibit useful functions. Can be manufactured.
In the invention concerning Claim 16, it becomes possible to improve the production amount of the molded object for baking per unit time, form the molded object for baking excellent in shape retention property, and to manufacture a high-quality fired body.
In the invention concerning Claim 17, it becomes possible to provide a high-quality fired body.

Hereinafter, embodiments of the present invention will be described in the following order.
(1) Description of fired compact and method for producing fired body:
(2) Configuration of manufacturing apparatus used in this manufacturing method:
(3) Actions and effects of the molded body for firing and the method for producing the fired body:
(4) Various modifications:

(1) Description of fired molded body and method for producing fired body:
FIG. 1: has shown the outline of the manufacturing method of the molded object for baking and fired body concerning one Embodiment of this invention with the flowchart. The method for producing the fired body includes a material including at least a filler M1 made of a finely divided inorganic, metal, or wood-based material, and a resin M2 in a molten state (fluid state) equal to or less than the filler. An extrusion process S1 mixed in the extrusion mechanism A1 and extruded in an irregular shape, and the irregularly shaped material M4 extruded from the extrusion mechanism A1 are introduced into the predetermined introduction part A2 while being irregularly shaped. A forming material generating step S2 for generating a forming material M6 from the material M4, a forming step S3 for forming the formed forming material M6 by a predetermined forming mechanism A4 to form a fired molded body M7, and the forming material S6 are formed. A firing step S4 for firing the fired compact M7 to produce a fired body M8. Here, the fired molded body M7 is a molded body for firing to form the fired body M8, and the molding material M6 is a material that can be molded into the shape of the fired molded body by the molding mechanism A4.

  The filler M1 includes fine particles such as alumina, aluminum nitride, silica such as alumina silica, zirconia silica and fly ash, silicon, silicon nitride, silicon carbide, titania, zirconia, glass, slag, a mixture thereof, etc. Or finer particles than pellets), inorganic materials such as gold, silver, iron, stainless steel, chromium alloy, nickel alloy, bronze, etc., wood powder, wood wool, wood fragments, wood fiber, wood pulp, A fine particulate wood material such as a wood fiber bundle can be used. The inorganic material may be a crystalline material or an amorphous material such as amorphous glass. When forming a fired molded body using a wood-based material, firing the fired molded body in an inert gas atmosphere such as nitrogen gas, carbon dioxide gas or argon gas without burning the wood-based material It can be carbonized to form a fired body. The particle size of the fine filler M1 is preferably 0.001 to 1000 μm, and may be 0.02 to 500 μm or 0.1 to 100 μm in order to make the particle sizes more uniform. When the particle size of the filler M1 is adjusted, the strength of the fired molded body and the fired body can be adjusted.

The resin M2 includes thermoplastic resins such as polypropylene (PP), polyethylene, polystyrene, polybutene, polymethyl methacrylate, vinyl chloride, polyamide (nylon), polycarbonate, polyacetal, polybutylene terephthalate, polyethylene terephthalate, and mixtures thereof. A thermosetting resin such as a phenol resin, a urea resin, a melamine resin, an unsaturated polyester resin, an epoxy resin, or a mixture thereof can be used. Polyolefin resins such as PP and polyethylene are suitable resins in that a molding material can be generated and easily molded into the shape of a molded article for firing, and also suitable in that they are incinerated and removed during firing. It is a good resin.
If the resin M2 is in a molten state, it can be mixed with the filler M1 as it is to obtain a softened material. When the resin M2 is a thermoplastic resin, the resin M2 can be charged as a solid raw material to the kneading extruder with a heater. Here, the thermoplastic resin is a resin having an MFR of 10 g / 10 min or more (preferably 100 g / 10 min or more) at the temperature of the molding material heated by the second heating mechanisms A24, A31, A41 of FIGS. Then, good fluidity can be obtained when molding from a molding material into the shape of a fired molded body, and the production amount of the fired molded body per unit time can be improved. In the case of a thermoplastic resin such as PP, generally, the smaller the molecular weight, the greater the fluidity (the MFR becomes larger). Therefore, when a relatively low molecular weight thermoplastic resin is used, good fluidity can be obtained. When PP is used as the resin, molding is performed from a molding material to a fired molded body at about 200 to 230 ° C., and therefore, PP having an MFR within this temperature range of 10 or more (100 or more) may be used. Note that the PP test conditions defined in the ISO standards related to JIS K7210 are the conditions M (test temperature 230 ° C.) in Appendix A Table 1 of JIS K7210, and therefore the MFR under these conditions is 10 or more (100 PP) as described above may be used. In addition, since the molding from the molding material to the molded body for firing becomes easier as the resin has a larger MFR under the same conditions, the blending ratio of the resin in the material can be further reduced.
If the resin M2 is a compound that does not contain an inorganic component or a metal component, it does not remain when the fired molded body is fired, so that a high-quality fired body having no unnecessary components can be produced. As the resin M2 that does not remain at the time of firing, a polymer compound composed of only C (carbon) atoms, H (hydrogen) atoms, and O (oxygen) atoms is very preferable, but a high molecular weight that further contains halogen atoms, nitrogen atoms, and sulfur atoms. Molecular compounds may also be used.

The amorphous material M4 may be generated only from the filler M1 and the resin M2, but the third material M3 may be mixed together to generate the amorphous material. If there is a fourth material, a fifth material, etc., these may be mixed together. In such a case, if the third material M3, the fourth material,... Are fine particles, they are easily mixed with a material containing at least a filler and a resin. It is preferable in that it can be made uniform.
In this embodiment, the weight ratio of the resin M2 in the material is set to be equal to or less than the weight ratio of the filler M1, and the filler is highly filled. A preferable blending ratio of the filler M1 and the resin M2 is 1 to 49% by weight (more preferably 5 to 30% by weight) of the resin with respect to 51 to 99% by weight (more preferably 70 to 95% by weight) of the filler. . The reason why the filler is 51% by weight (70% by weight) or more is to reduce the degree of shrinkage when firing the fired molded body so that the fired body is sufficiently formed into a desired shape. The reason for setting it to (5% by weight) or more is to sufficiently improve the shape retention of the fired molded article.

As the third material M3, for example, if a compatibilizer having compatibility with the resin M2 and having a hydrophilic group is used, the familiarity between the filler and the resin can be improved, and the molded body for firing is more Homogenize to make the fired body more homogeneous. Examples of hydrophilic groups include functional groups such as hydroxyl groups (hydroxyl groups), carboxyl groups, aldehyde groups, and sulfo groups. If the compatibilizing agent is a polymer compound consisting of only C atoms, H atoms and O atoms, or if it is a polymer compound further containing a halogen atom, a nitrogen atom, or a sulfur atom, the phase is obtained when the fired molded article is fired. Since no solubilizer remains, a high-quality fired body free from unnecessary components can be obtained.
A preferable blending ratio in the material is 51 to 99% by weight (more preferably 70 to 95% by weight) of the filler, and 1 to 49% by weight (more preferably 5 to 30% by weight) of the resin and the compatibilizer. And only the compatibilizing agent is 0.1 to 5% by weight. The reason why the filler is 51% by weight (70% by weight) or more is to reduce the degree of shrinkage when firing the fired molded body so that the fired body is sufficiently formed into a desired shape. The reason why the total amount is made 1% by weight (5% by weight) or more is to sufficiently improve the shape retention of the fired molded article. Moreover, the preferable compounding ratio of resin and a compatibilizer is 1 to 50 weight% of compatibilizers with respect to 50 to 99 weight% of resin.

When an acid-modified synthetic resin obtained by adding a predetermined organic acid to a raw material of a synthetic resin that is compatible with the resin M2 contained in the raw material is used as a compatibilizing agent, Since no organic acid remains, a high-quality fired body can be obtained. The synthetic resin compatible with the resin M2 may be the synthetic resin M2 itself or a synthetic resin different from the resin M2. As the organic acid, maleic acid that imparts a hydrophilic group to the resin can be used, but an organic acid having a carboxyl group such as fumaric acid may be used. Since an acid-modified synthetic resin obtained by modifying a synthetic resin with an organic acid has properties similar to those of a synthetic resin that is not normally modified, only the acid-modified synthetic resin may be used as the resin M2.
In order to produce an acid-modified synthetic resin obtained by modifying a thermoplastic resin with maleic acid, addition polymerization may be performed by adding maleic acid to the raw material of the thermoplastic resin before addition polymerization. Then, a carboxyl group which is one of hydrophilic groups is added to the polymer after addition polymerization. Therefore, the acid-modified synthetic resin has good compatibility with the filler M1.
In general, in order to produce an acid-modified synthetic resin obtained by modifying a synthetic resin with an organic acid, polymerization may be performed by adding an organic acid to the raw material of the synthetic resin before polymerization. Then, a carboxyl group is added to the polymer after polymerization, and the compatibility with the filler M1 is improved.

As the third material M3, a resin molding lubricant may be used. Then, since the slip between the fillers becomes good when forming from the forming material into the shape of the molded body for firing, it is possible to facilitate forming. Lubricants include fatty acid amides such as stearic acid amide, oleic acid amide, ethylene bis stearic acid amide, methyl laurate, methyl stearate, butyl stearate, isopropyl myristate, octyl stearate, lauryl laurate, stearyl long stearate Long fatty acid higher alcohol esters, behenine behenate, cetyl myristate, and the like, stearates such as zinc stearate, and the like can be used. If the lubricant is a polymer compound consisting only of C atoms, H atoms and O atoms, or if it is a polymer compound further containing a halogen atom, a nitrogen atom and a sulfur atom, the lubricant remains when the fired molded article is fired. Therefore, a high-quality fired body free from unnecessary components can be obtained.
A preferable blending ratio in the material is 1 to 49% by weight (more preferably 5 to 30% by weight) of the total of the resin and the lubricant with respect to 51 to 99% by weight (more preferably 70 to 95% by weight) of the filler. Yes, only the lubricant is 0.1 to 5% by weight. The reason why the filler is 51% by weight (70% by weight) or more is to reduce the degree of shrinkage when firing the fired molded body so that the fired body is sufficiently formed into a desired shape. Is 1% by weight (5% by weight) or more in order to sufficiently improve the shape retention of the fired molded article. Moreover, the preferable compounding ratio of resin and a lubricant is 1-20 weight% of lubricants with respect to 20-99 weight% of resin.

A fibrous material may be used as the third material M3. Then, since the fibrous material makes the fired compact difficult to collapse, it becomes possible to form the fired compact by forming a fired compact excellent in shape retention. In addition to synthetic resin fibers that can be used as the resin M2, the fibrous materials include glass fibers, sepiolite (Si ₁₂ Mg ₈ O ₃₀ (OH) ₄ (H ₂ O) ₄ · 8H ₂ O), wollastonite ( Mineral fibers such as CaSiO ₃ ), asbestos (asbestos), magnesium whisker, and the like can be used. When the fibrous material is a polymer compound consisting of only C atoms, H atoms and O atoms, or a polymer compound further containing a halogen atom, a nitrogen atom and a sulfur atom, the fiber is formed when the fired compact is fired. Since no shaped material remains, a high-quality fired body free from unnecessary components can be obtained.
A preferable blending ratio in the material is 1.1 to 49% by weight (more preferably 5%) of the resin and the fibrous material with respect to the filler 51 to 98.9% by weight (more preferably 70 to 95% by weight). ~ 30 wt%), and only the fibrous material is 0.1-30 wt%. The reason why the filler is 51% by weight (70% by weight) or more is to reduce the degree of shrinkage when firing the fired molded body so that the fired body is sufficiently formed into a desired shape. Resin and fibrous material The reason why the total is 1.1 wt% (5 wt%) or more is to sufficiently improve the shape retention of the fired molded article. Under these conditions, the preferable blending ratio of the resin in the material is 1% by weight or more (more preferably 5% by weight or more).

In addition, you may further provide the silane coupling process which makes the filler M1 react by making a silane coupling agent react with a finely divided inorganic material or metal material. Then, the familiarity between the filler and the resin is improved, the fired molded body can be made more homogeneous, and the fired body can be made more homogeneous. Here, as the finely divided inorganic material or metal material, a material that can be used as the filler M1 can be used. The silane coupling agent has an ethoxy group or a methoxy group that gives a silanol group (Si—OH) by hydrolysis at one end of the molecule, and an organic functional group at the other end. As the silane coupling agent, an organosilane treatment reagent SiX ₁ X ₂ X ₃ X ₄ (X ₁ , X ₂ , X ₃ , X ₄ at least one of the reagents described in JP-A-8-252813 is about An unfunctionalized alkyl or alkenyl group having 10 to 35 carbon atoms, at least one of X ₁ , X ₂ , X ₃ and X ₄ is an alkoxy group or a halide) can be used. When a silane coupling agent is applied to a finely divided inorganic material or metal material using a silane coupling agent, hydrophobic organic functional groups are added to the finely divided inorganic material or metal material to impart hydrophobicity. The Therefore, the finely divided inorganic material or metal material has better compatibility with the resin M2.
The silane coupling treatment can be performed by, for example, a method described in JP-A-8-252813. That is, a finely divided inorganic material or metal material is sufficiently dispersed in water containing isopropyl alcohol or about 5 to 50% by volume of isopropyl alcohol so as to be uniform with a high-speed mixer, and octadecyltriethoxy is added to the resulting slurry. Silane is gradually added, and the mixture is stirred at about 60 ° C. for about 15 to 60 minutes, and then the cake-like surface-modified inorganic material or metal material is separated by a centrifugal separator at about 120 ° C. for about 5 to 10 hours. What is necessary is just to dry.

The blending amount of the silane coupling agent when the silane coupling agent is reacted with the finely divided inorganic material or metal material is preferably 0.1 to 15% by weight based on the finely divided inorganic material or metal material.
A preferable blending ratio in the material is 1 to 49% by weight (more preferably 5 to 30% by weight) of the resin with respect to 51 to 99% by weight (more preferably 70 to 95% by weight) of the filler subjected to the silane coupling treatment. %). The reason why the filler obtained in the silane coupling step is 51% by weight (70% by weight) or more is that the degree of shrinkage is reduced when the fired molded body is fired, and the fired body is sufficiently formed into a desired shape. The reason why the resin is 1% by weight (5% by weight) or more is to make the shape retention of the fired molded body sufficiently good.

The extrusion mechanism A1 mixes the raw material containing at least the filler M1 and the molten resin M2, and extrudes it in an irregular shape. As the extrusion mechanism, various extruders such as a single screw kneading extruder and a twin screw kneading extruder can be used. The extruded amorphous material M4 is introduced into a predetermined introduction part A2.
2 and 3 show an example of a method for manufacturing a molded body for firing using a thermoplastic resin M11 as the resin M2 and a compatibilizer M12 as the third material M3. When the thermoplastic resin is used, it is preferable to heat the material including at least the filler M1 and the thermoplastic resin M11 by the first heating mechanism A11 because the thermoplastic resin M11 can be in a molten state. In this case, the extrusion step S1 has a first heating step in which a material including at least the filler and the thermoplastic resin is heated by the first heating mechanism to bring the thermoplastic resin into a molten state. The material heated in one heating step is extruded in an indeterminate state without being mixed and molded by the extrusion mechanism A1. If the third material M3 such as the compatibilizing material M12 is a material that melts by heating, the third material M3 can be supplied to the extrusion mechanism A1 as a solid raw material.

In the introduction part A2 for introducing the amorphous material M4, only the amorphous material M4 may be introduced, or the second material M5 having at least a second resin having different physical properties from the resin is introduced. Also good. If there is a fourth material, a fifth material, etc., these may be mixed together. In such a case, if the second material M5, the fourth material, the fifth material,... Are fine particles, they are easily mixed with the amorphous material. This is preferable in that it can be made homogeneous.
As the second resin, a resin that can be used for the resin M2 can be used.

The molding material generation mechanism A3 generates the molding material M6 from the amorphous material M4 introduced into the introduction part A2. In the example of FIG. 2, the irregular shaped material M4 introduced into the introduction part is pulverized by a predetermined pulverization mechanism A12 (pulverization step S5), and the pulverized material (pulverized product M13) is pelletized by the pellet forming mechanism A13. It is formed into a shape (pellet forming step S6) and used as a pellet M14 (forming material). In this case, steps S5 and S6 become the molding material generation step S2, and mechanisms A12 and A13 become the molding material generation mechanism A3. Furthermore, you may provide the 1st cooling process which cools the raw material for shaping | molding of a pellet shape with a 1st cooling mechanism. The pulverization step may be omitted, and the amorphous material M4 introduced into the introduction part may be directly formed into a pellet shape by the pellet forming mechanism A13. When the pulverization step S5 is provided, the fired compact is made more uniform to make the fired body more uniform, and the pellet M14 is more easily broken when being molded from the pellet M14 into the shape of the fired compact M7. It is possible to further improve the production amount of the molded body for firing per unit time.
For example, the pellet forming mechanism extrudes a soft material from each extrusion port of a die having a large number of extrusion ports having a diameter of about 3 to 5 mm into a substantially rod shape and cuts it into a pellet shape by cutting it into a length of about 3 to 7 mm. A molding machine can be used.
In the example of FIG. 3, the irregular shaped material M4 introduced into the introduction part is pulverized by a predetermined pulverization mechanism A12 (pulverization step S5), and the pulverized material (pulverized product M13) is used as a molding material M6. In this case, the crushing step S5 becomes the molding material generation step S2, and the crushing mechanism A12 becomes the molding material generation mechanism A3.

The forming mechanism A4 forms the forming material M6 into the shape of the fired formed body M7. In the example of FIG. 2, a thermoplastic resin is contained in the material, and an extrusion molding apparatus A20 with a heater (second heating mechanism) A24 (molding mechanism A4 is used) using a molding material M6 in a pellet shape. The material is formed by extrusion molding. When the pellet M14 is put into the hopper A21 of the extrusion molding apparatus A20, the apparatus A20 heats and softens the pellet M14 with the heater A24 (second heating step), and mixes the softened pellet M14 with the extruder A22. Then, it is extruded from a predetermined die, cut into a predetermined length by a cutting machine A23, and molded. You may provide the 2nd cooling process which cools a molded article with the 2nd cooling mechanism and sets it as the molded object M7 for baking. In this way, the fired molded body M7 is manufactured.
Instead of the extrusion molding apparatus A20, the material may be molded by injection molding with an injection molding apparatus A30 (having a molding mechanism A4) with a heater (second heating mechanism) A31. When the pellet M14 is put into the injection molding apparatus A30, the apparatus A20 heats and softens the pellet M14 with the heater A31 (second heating step), mixes the softened pellet M14, and forms a predetermined shape from a predetermined die. Are injected (extruded) into a mold and molded into a predetermined shape. In this case as well, a second cooling step may be provided in which the molded product is cooled by the second cooling mechanism to form the fired molded body M7.

When a thermoplastic resin is used as the resin M2, it is preferable to heat the pellet M14 with the second heating mechanisms A24 and A31 because the pellet M14 can be softened.
In the example of FIG. 2, the molding step S3 includes a second heating step in which the pellet M14 is heated and softened by the second heating mechanism, and the pellet M14 softened in the second heating step is formed by the molding mechanism A4. The molded body for firing M7 is manufactured by mixing by pressing and extruding from the die.

  When performing extrusion molding or injection molding when manufacturing a molded article for firing, it is not easy to uniformly knead the raw materials in the kneading stage if the material is in powder form. Therefore, the molding material M6 has a pellet shape so that it can be molded into the shape of the fired molded body by a molding mechanism that molds by extrusion molding or injection molding. Of course, it can be formed into a shape of a fired molded body by press molding using a pellet-shaped molding material.

  In the example of FIG. 3, the pulverized product M13 is formed by press molding using a press molding apparatus A40 (having a molding mechanism A4) with a heater (second heating mechanism) A41 using the pulverized molding material M6. To do. When the pulverized product M13 is charged into the press molding apparatus A40, the apparatus A40 pushes the pulverized product M13 into a mold having a predetermined shape and heats it up to a temperature at which the thermoplastic resin is in a molten state by the heater A41 while applying pressure. . When the mold is opened, a fired molded body M7 is obtained. You may provide the 2nd cooling process which cools a molded article with the 2nd cooling mechanism and sets it as the molded object M7 for baking. In the example of FIG. 3, in the molding step S3, the pulverized product M13 is molded by press molding with a molding mechanism to produce a fired molded body M7.

  If the molding material is in powder form, it is not easy to perform extrusion molding or injection molding, but it can be easily molded into the shape of a molded body for firing by a molding mechanism that performs molding by press molding.

When a synthetic resin that is liquid (fluid state) at normal temperature (for example, 20 ° C.) is used as the resin M2, it is not necessary to melt the resin and soften the molding material, so the first heating mechanism A11 (first heating step) And the second heating mechanisms A24, A31, A41 (second heating step) are not required. When a thermosetting resin is used as the liquid synthetic resin, a fired molded body using a thermosetting resin as a raw material, which has not been conventionally possible, can be manufactured.
Through the above steps, a fired molded body is manufactured.

The firing mechanism A5 produces the fired body M8 by firing the fired molded body M7. As the firing mechanism, various firing apparatuses such as a firing apparatus for firing by placing a fired compact in a batch-type firing furnace and a firing apparatus for firing by passing the fired compact in a tunnel-type firing furnace may be used. it can. Various heat sources such as an electric heater and a gas burner can be used as a heat source for raising the temperature of the firing furnace. As temperature at the time of baking, when using an inorganic or metal raw material for the filler M1, 550-2000 degreeC is preferable and 800-1600 degreeC is further more preferable. A temperature of 550 ° C. (800 ° C.) or higher is preferable in that the resin M2 can be surely incinerated and removed. Note that when the firing temperature is set to a relatively low temperature of about 800 ° C., an amorphous (amorphous) fired body is easily obtained, and when the firing temperature is set to a relatively high temperature of about 1400 ° C., a crystallized fired body is easily obtained. .
A fired body is manufactured by the above steps.

(2) Configuration of manufacturing apparatus used in this manufacturing method:
FIG. 4 is an external side view of an embodiment of the pellet manufacturing apparatus 10 used for carrying out the method for manufacturing a main body for firing, and FIG. 5 is an external top view of the pellet manufacturing apparatus. The device 10 generally includes devices 11, 12, 13, 20, 14 and a control panel 15. The control panel 15 is provided with a plurality of operation buttons and an operation display for monitoring the setting of operation conditions and the operation state of the apparatus 10 on the front surface. An operator of the apparatus 10 performs various operations using the control panel 15. In addition, it demonstrates as what uses a thermoplastic resin as resin M2.
The material supply device 11 is formed in a hollow, substantially cylindrical shape, and includes a hopper device 11a having an opening 11a1 on the upper surface. Inside the hopper device 11a, a stirring blade 11a2 and a stirring blade connection disk 11a3 to which the stirring blade 11a2 is connected are arranged. The stirring blade connection disk 11a3 is connected to the stirring blade through a belt 11a4. It is connected to the drive motor 11a5. The drive of the motor 11a5 is transmitted to the disk 11a3 via the belt 11a4, and the disk 11a3 and the stirring blade 11a2 are rotationally driven. When at least the particulate filler and the fragment-shaped thermoplastic resin raw material are put into the hopper device 11a, the materials accommodated in the device 11a are mixed while being stirred in the granular state, and conveyed from the mixed material supply port 11a6. Supplied to the device 12.

  The material conveyance device 12 receives the mixed material supplied from the mixed material inlet 12a connected to the mixed material supply port 11a6. A screw shaft 12c in which a part (the right side in FIGS. 4 and 5) is inserted into the pellet forming apparatus 20 is disposed inside the substantially cylindrical hollow tube 12b. The screw shaft 12c is a screw having a plurality of flight spiral threads formed along the axial direction. The material flowing in from the inflow port 12a is accommodated in a space formed by the hollow tube 12b, the screw shaft 12c, and the screw thread. The screw shaft 12c is connected to a screw shaft drive motor 12e via a gear portion 12d. When the screw is rotated by driving the motor 12e, the material accommodated in the space formed by the hollow tube 12b, the screw shaft 12c and the screw thread is a predetermined shape formed by the rotating operation. Based on the extrusion speed, the fluid is extruded toward the fluid outlet 12f while being mixed. At this time, the material is heated by the material heating device (heating mechanism) 13 provided in the material conveying device 12 and is softened by melting the thermoplastic resin. Therefore, the extruded material is in a softened state. The apparatus 13 generally includes a plurality of heater portions 13a having heating elements, and a plurality of blower portions 13b corresponding to the heater portions 13a. The air in the hollow tube 12b is heated by blowing air heated to a high temperature by the heating element of the heater unit 13a to the hollow tube 12b by the blower unit 13b.

  Here, the heater part should just be raised to the temperature which fuses a thermoplastic resin, and should just determine the heating capability of a heater according to the kind of thermoplastic resin. For example, when PP is used as the thermoplastic resin, the temperature is about 200 to 230 ° C., and when polyamide is used, the temperature is about 270 to 290 ° C. The ability of the material conveying device 12 to convey the material may be determined according to the properties such as the viscosity of the softened material.

FIG. 6 is a perspective view of the main part of the pellet forming apparatus 20, and FIGS. 7 and 8 are vertical sectional views as seen from the direction B of FIG. In FIG. 7, the screw shaft 12c and the screw thread are shown in side view. Hereinafter, the arrangement of each member will be described based on the vertical and horizontal relationships with reference to FIGS.
The pellet forming apparatus 20 has a cylindrical metal outer cylinder portion 21 centering on the direction of extrusion of the softened material, and a metal attached to the end of the outer cylinder portion 21 on the material outlet side (right side in the figure). A crusher (grinding mechanism) 30 provided with an inlet portion 31 that is a member and an introduction portion 31 that introduces an unshaped material m1 to be pushed out by being installed with the opening 31a facing upward on the lower side of the outlet portion 22. The molding machine container 23 in which the pulverized material introduction part 24 for introducing the material m2 pulverized by the pulverizer 30 is formed, the two pressing rollers 25 and 25 provided in the container 23, and the molding machine container 23, a metal die face cutter unit 26 that is rotatably attached to the lower side of the motor 23, an electric motor 27 that rotationally drives the die face cutter unit 26, and the like.
A material inlet 21 a is provided on the left side of the outer cylinder portion 21, and the softened material flows into the material inlet 21 a from the material conveying device 12. The distal end portion (left end portion) of the screw 12g is inserted into the outer cylinder portion 21, and the softened material conveyed into the outer cylinder portion 21 is pushed rightward while being mixed by the rotational operation of the screw 12g. Then, it is pushed to the right side from the outlet portion 22 and falls into the metal crusher hopper 32 as an irregular shaped material m1. In addition, the raw material conveyance apparatus 12, the outer cylinder part 21, and the exit part 22 comprise an extrusion mechanism.
The outlet 22 is not a molding die, but is formed with a single opening 22a that is much larger in diameter than the pellets to be produced. The softened and mixed material passes through the opening 22a. Extruded in an irregular shape without being molded.

Conventionally, instead of the outlet portion 22, a die having a large number of through holes having substantially the same diameter as the pellet is attached to the right end portion of the outer cylinder portion 21. However, since the flow rate of the material is small even when the thermoplastic resin is melted in a material with a small blending ratio of the thermoplastic resin, a large resistance is generated in the die portion, the extrusion flow rate of the material is small, and a large amount per unit time. A pellet could not be formed. In the present embodiment, such a die is not attached to the outer cylinder portion 21, and no great resistance is generated at the outlet portion 22, so that the extrusion flow rate of the material is increased.
In addition, the fluidity of the material is measured by measuring the mass of the material extruded from the melt flow rate measuring device per unit time in accordance with MFR (melt mass flow rate, also simply referred to as melt flow rate) defined in JIS K7210. Can be expressed by a flow rate (unit: g / 10 min) determined by This flow rate is MFR obtained in accordance with JIS K7210. Hereinafter, this flow rate is also simply referred to as MFR.
Usually, the mixing ratio of the fine particulate filler and the thermoplastic resin is 70 to 99.9: 0.1 to 30 in a weight ratio, and the raw material having a large amount of filler is indefinite in the extrusion mechanism using the raw material as a sample. When the temperature of the material at the outlet position where the material is extruded (P1 in FIG. 7) is the test temperature θ (° C.), the load Mnom is 2.16 kg, and the MFR according to JIS K7210 is measured, the required MFR is 1. 0 g / 10 min or less. Since the fluidity of the sample is smaller as the MFR is smaller, a material with more filler is less fluid. For example, for a material containing 80% by weight of polypropylene (thermoplastic resin) with an MFR of 50 g / 10 min and 20% by weight of finely divided wood powder having a particle size of 1 mm or less, the material temperature of 180 ° C. at the outlet of the extrusion mechanism is the test temperature. When MFR is measured with θ and a load Mnom of 2.16 kg, the MFR becomes 0.0 g / 10 min or cannot be measured.
For a material with low fluidity, the material discharge pressure Pe (corresponding to the outlet position P1) in an extrusion molding machine in which a pellet forming die (extruding port is 1 to 8 mm in diameter) is attached to the end of the outer cylinder. The pressure of the material at the position) becomes too large, making it difficult to extrude, making it impossible to mass produce pellets. The discharge pressure Pe can be measured by inserting a detection unit of a pressure gauge at a position corresponding to the outlet position P1 in the extruder. In particular, in a low-fluidity material with a discharge pressure Pe of 25.0 MPa or more, an extrusion molding machine equipped with a pellet forming die does not perform pellet molding from the viewpoint of machine durability. In general, a material in which the mixing ratio of the fine filler and the thermoplastic resin is 70 to 99.9: 0.1 to 30 by weight ratio has a discharge pressure Pe of 25.0 MPa or more with the resin softened by heating. However, even with such a material with low fluidity, the pellet manufacturing apparatus of the present invention can extrude the material while kneading with an extrusion mechanism, and can mass-produce pellets.

In the present embodiment, the cross-sectional area S1 of the opening 22a of the outlet portion is defined as the cross-sectional area S0 of the opening portion at the end portion on the outlet portion 22 side of the outer cylinder portion 21 (the cross-sectional area of the portion surrounded by the inner surface of the outer cylinder portion) As described above, the discharge pressure Pe of the material is reliably reduced to 5.0 MPa or less so that the material is smoothly pushed out from the outlet. Although FIG. 7 shows the case of S1 = S0, it may be S1> S0. As long as the cross-sectional area at the end portion on the outlet side of the outer tube portion is to be compared, the same can be said for an extruder having an oblique axis screw. Of course, even in the case of S1 <S0, it is possible to smoothly extrude the material if an opening having a diameter much larger than the pellet to be formed is formed at the outlet. From the viewpoint of the discharge pressure of the material, the opening at the outlet may be shaped so that the discharge pressure Pe of the material is 5.0 MPa or less, more preferably 3.0 MPa or less, and even more preferably 1.0 MPa or less. Then, since a large amount of amorphous materials can be extruded per unit time, pellets can be mass-produced. Here, if the cross-sectional area S1 of the opening of the outlet portion is increased, the discharge pressure decreases, and if S1 is decreased, the discharge pressure increases. Therefore, the discharge pressure Pe can be adjusted by adjusting the cross-sectional area S1. .
The crusher hopper 32 temporarily stores the irregular shaped material m1 pushed out from the opening 22a of the outlet, and supplies the material m1 from the lower opening 32b into the cylindrical metal crushing chamber 33 having a substantially vertical direction as a central axis. be able to. Since the opening 32a of the hopper is separated from the outlet portion 22 and is located on the lower side of the outlet portion 22, the extruded material m1 does not obstruct the extrusion of the subsequent material m1, and the hopper 32 opens the outlet portion. The amorphous material m1 extruded from 22a can be accommodated. And the predetermined introducing | transducing part 31 which introduces the raw material extruded from the extrusion mechanism with an indefinite shape is formed in the hopper 32 and the crushing chamber 33. Of course, the introduction part may be structured so as not to be separated from the extrusion mechanism and partially connected to the extrusion mechanism.
Further, as shown in FIG. 9, a conveyor (for example, a belt conveyor) 51 may be provided that places and transfers an irregular shaped material m <b> 1 from the lower side of the outlet portion 22 of the extrusion mechanism to the upper side of the hopper 32. That is, the amorphous material m1 extruded from the extrusion mechanism is placed on the conveyor 51, transferred in the direction of the hopper 32, accommodated in the hopper 32, and supplied into the crushing chamber 33. In this case, the introduction unit 50 is configured by the conveyor 51, the hopper 32, and the crushing chamber 33.

The pulverizer (pulverizing mechanism) 30 includes a pulverization chamber 33 in which an upper opening communicating with the hopper 32 and a lower opening 32b of the hopper is formed below the hopper 32, and a lower portion in the pulverization chamber 33 in the vertical direction. A metal mounting table 34 on which an indeterminate material is mounted that can be rotated with the rotation axis directed, and a columnar shaft member 35a, 35a directed in the left-right direction on the mounting table 34 as a rotation axis. The table 34 is rotationally driven via a plurality of metal crushing rollers 35 and 35 that can roll on the table 34 and a columnar rotational drive shaft 36a disposed in the vertical direction. An electric motor 36, a powder transport machine 37 for transferring the pulverized material to a powder discharge port (not shown) opened downward in the upper part of the molding machine container 23, and the like are provided. The shaft members 35 a and 35 a are fixed to the side wall of the crushing chamber 33. A cylindrical metal powder storage chamber 33a having substantially the same diameter as the pulverization chamber 33 is provided below the pulverization chamber 33 (from the lower surface of the mounting table 34), and the storage chamber 33a is pulverized. A powder suction port 37 b through which the subsequent material is sucked into the powder transport machine 37 is formed.
In the pulverizer 30, the motor 36 is always energized, and the mounting table 34 is rotationally driven through the rotation drive shaft 36a. Then, on the upper surface of the mounting table 34, the crushing roller is rotated about the horizontal direction as a result of the rotational movement about the vertical direction of the table 34, and the amorphous material introduced into the crushing chamber 33 is Then, it is pulverized between the mounting table 34 and the peripheral surfaces of the pulverizing rollers 35 and 35. Here, the introduced material is a material in which a thermoplastic resin is familiar with the fine filler, and the softened material having the filler familiar with the resin is pulverized and homogenized. Further, the air blower of the powder transport machine 37 is always energized, and the material that has been crushed and dropped into the housing chamber 33a from the space 33b between the inner peripheral surface of the pulverizing chamber 33 and the outer peripheral surface of the mounting table 34 is powdered. The powder is sucked into the powder transport machine 37 from the body suction port 37b, is transferred obliquely upward to the upper side of the powder discharge port, and is discharged downward from the powder discharge port 37a. Then, the pulverized material falls and is accommodated in the molding machine container 23.
Various known pulverizers can be used as the pulverization mechanism.

  The molding machine container 23 includes a cylindrical container outer cylinder portion 23a having a substantially vertical direction as a central axis, and a bottom disc 23b attached so as to close the lower opening of the container outer cylinder portion 23a. It is configured. In the present embodiment, a large number of through-holes 23d having a diameter of 1 mm or more and 8 mm or less, for example, a diameter of about 3 to 5 mm, are formed in the bottom disk 23b serving as the bottom of the molding machine container 23 in a range larger than the pulverized material particles. It is formed in a substantially vertical direction. Since the upper opening 23c of the outer cylinder portion 23a for the container is separated from the powder discharge port 37a of the pulverizer and is located below the discharge port 37a, the container 23 for the molding machine is located downward from the discharge port 37a. The crushed material M2 discharged toward the container can be accommodated. Then, the pulverized material introduction part 24 for introducing the material pulverized by the pulverization mechanism is formed in the molding machine container 23. Of course, the pulverized material introduction part may be structured so as not to be separated from the pulverizing mechanism but partially connected to the pulverizing mechanism.

As shown in FIG. 10, the bottom disc 23b has a large number of substantially circular through holes 23d (in the figure, 16 concentric circles × 2 rows). The attachment position of the die face cutter unit 26 is indicated by a dotted line. The crushed material extruded from each through-hole 23d is substantially rod-shaped.
The push-in rollers 25 and 25 provided in the molding machine container 23 are rotatably attached to both ends of a substantially columnar rod-shaped member 25a installed substantially horizontally. The rod-like member 25a is fixed to a rotating shaft member 25b provided in a substantially vertical direction at an intermediate portion from both ends, and is provided so as to be rotatable about the rotating shaft member 25b as a central axis. The rotating shaft member 25b is attached to a roller driving electric motor 25c. When the motor 25c is energized and operated to rotate the rotating shaft member 25b, the rollers 25 and 25 at both ends of the rod-shaped member 25a rotate around the bottom disk 23b while rotating themselves (in FIG. 6). Counterclockwise). At this time, the rollers 25 and 25 rotate by themselves due to the frictional force between the upper surface of the bottom disk 23b and the rollers 25 and 25 (counterclockwise in the roller 25 shown in FIG. 7). The crushed material is pushed in from one opening (upper opening) of the many through holes 23d, and pushed out from the other opening (lower opening) in a substantially rod shape. The number of pushing rollers may be one or three or more.

  As shown in FIGS. 8 and 10, the die face cutter unit 26 includes a cutter table 26 a serving as an attachment unit to the electric motor 27 for driving the cutter, and a plurality of (this embodiment) attached and fixed to the cutter table 26 a. 2) cutters 26b. In the present embodiment, each cutter 26b slides on the lower surface of the bottom disk 23b and rotates, so that the substantially rod-shaped material pushed downward from the lower opening of the through-hole 23d is made more than the particles of the material after pulverization. Cut in a large range to a length of 1 mm to 30 mm, for example, about 3 to 7 mm in length. As a result, the softened material is formed into a pellet shape. A molding machine container 23 having a plurality of through holes 23d, push rollers 25, 25 and mechanisms 25a to 25c for driving the push rollers, a die face cutter unit 26 having a cutter 26b, and a motor 27 are provided. Configure the pellet forming mechanism.

The material molded into the pellet shape falls into the cooling tank 40, is cooled and solidified, and is collected from the cooling tank 40 as pellets m3. The cooling tank 40 is filled with cold water cooled by a cooler (not shown), and solidifies the molded material falling from the pellet forming apparatus 20 with cold water. The cooling tank 40 and the cooler constitute a first cooling mechanism. By immediately solidifying the molded material, it is possible to prevent the molded materials from adhering to each other.
The solidified pellets flow into the sorting and conveying device 14 from the pellet inlet 14a. The sorting / conveying device 14 has a sorting / conveying network, a conveying net vibration motor, and a pellet storage section in which a large number of substantially circular small holes having a predetermined diameter are formed. The pellets are sequentially put into the sorting and transporting network, and the sorting and transporting network is vibrated by the transporting network vibration motor, whereby the size is sorted at the small holes of the sorting and transporting network. The pellets remaining on the sorting and conveying network move toward the pellet collecting unit on the sorting and conveying network, and are accommodated in the pellet accommodating unit by a cyclone (not shown). Also, the pellets that have fallen from the sorting and conveying network are collected and reused.

The produced pellets can be formed into the shape of a fired molded body using a general-purpose resin molding extruder or injection molding machine. As the extruder, various devices such as a single screw kneading extruder and a twin screw kneading extruder can be used. For example, as shown in FIG. 11, a hopper 61, a cylindrical metal outer cylinder portion 62 centering on the direction of extrusion of the softened material, and an end portion on the material outlet side (right side in the figure) A metal die 63 attached to the screw, a screw 64 inserted into the outer cylinder part 62, a screw shaft drive motor 65 for rotationally driving the screw, and the outer cylinder part 62 to heat the inside of the outer cylinder part to a predetermined temperature. A single screw kneading extrusion molding machine 60 with a heater provided with a heating machine (second heating mechanism) 66 to be performed and a cutter 67 provided on the outer side (right side) of the die 63 can be used. The extrusion molding machine 60 extrudes the softened material from the extrusion port 63a of the die 63 and forms it into the shape of a fired molded body. The material molded into the shape of the fired molded body is cooled and solidified in a cooling tank (not shown), and recovered as a fired molded body M7 from the cooling tank. Cold water cooled by a cooler is supplied to the cooling tank, and the cooling tank and the cooler constitute a second cooling mechanism. By immediately solidifying the molded material, it is possible to prevent the fired molded bodies from being bonded to each other.
Moreover, as an injection molding machine, for example, it has the same structure as each part 61-66 of the said extrusion molding machine 60, and as shown in FIG. 12, it was supported on this base part 71 so that a vertical movement was possible. A lower mold 72, a cylinder (not shown) for moving the lower mold 72 up and down, an upper mold 73 disposed so as to be openable and closable so as to face the upper surface of the lower mold 72, and on the base 71, the lower mold 72 A support portion 74 provided on the left side for rotatably supporting the upper mold 73, a motor (not shown) for rotating the upper mold 73, and a space between the lower mold 72 and the upper mold 73 and the extrusion port 63a. An injection molding machine 70 having an injection port 75 provided on the upper surface of the upper mold 73 in FIG. The injection molding machine injects a softened material into a space between both molds 72 and 73 and molds it into the shape of a fired molded body. When the molds 72 and 73 are cooled by a cooling mechanism (not shown), the injected material is solidified, and a fired molded body M7 is formed.

  The manufactured molded body for firing M7 can be made into a fired body M8 using a general-purpose firing apparatus. For example, as shown in FIG. 13, a batch-type baking apparatus 80 including a baking furnace 81 provided with a plurality of shelves 81 a in the furnace, and a heat supply device 82 that supplies heat to the furnace and raises the temperature to a predetermined temperature. Can be used. The heat supply device 82 can be configured to energize the electric heater with an amount of current corresponding to the set temperature, but can also be configured with a gas burner or a gas burner alone. The firing apparatus produces a fired body by firing the fired molded body M7 placed on the shelf 81a at a predetermined temperature.

In the case of omitting the crushing mechanism when generating the pellet-shaped molding material, the crusher 30 is omitted in FIG. 6 and the molding machine container is located below the outlet 22 where the irregular shaped material is extruded. 23 may be disposed, and the material extruded from the outlet 22 in an irregular shape may be introduced into the molding machine container 23 in an irregular shape. The configuration of the pellet manufacturing apparatus in this case is the same as the configuration of the pellet manufacturing apparatus disclosed in Japanese Patent Application Laid-Open No. 2004-17502.
Further, when generating the pulverized molding material, the pellet molding mechanisms 23 to 25 are omitted in FIG. 6, and the pulverized material discharged from the powder discharge port 37a of the pulverizer is used as the molding material. do it. In this case, the pulverized molding material is put into a press molding apparatus with a heater, and the molding material is pushed into a mold having a predetermined shape by the press molding apparatus and heated to soften the molding material. When the pressure is applied, it is molded into the shape of the fired molded body. And if a metal mold | die is opened, the molded object for baking can be taken out.

(3) Actions and effects of the molded body for firing and the method for producing the fired body:
When at least a particulate filler and a thermoplastic resin equal to or less than the weight of the filler are charged into the material supply device 11, the material conveying device 12 conveys the charged materials toward the pellet forming device 20 while mixing them. At this time, since the material heating device 13 heats the material, the thermoplastic resin is melted and the material is softened. When PP is used as the resin, the material is heated so that the temperature is about 200 to 230 ° C., which is the same as the temperature of heat-melting at the time of molding from the molding material to the fired molded body. Here, since the raw material is highly filled with filler, even if the resin is melted, the solid content is large, so that the fluidity does not become too large and softens to such an extent that it can be pulverized. The material conveying device 12 pushes the softened material into the outer cylinder portion 21 of the pellet forming device while mixing with the screw 12g. Since the materials are mixed, an indeterminate material in which the resin is familiar (compatibilized) with the filler is formed. When a compatibilizing agent is added to the material, an indeterminate material in which the resin is more familiar with the filler is formed. In addition, when a filler obtained by reacting a silane coupling agent is used, an amorphous material in which the resin is more familiar with the filler is formed. The softened material is extruded in an indefinite shape without being molded. Here, since the cross-sectional area S1 of the opening of the outlet portion is set to be equal to or larger than the cross-sectional area S0 of the opening portion at the outlet side end portion of the outer cylinder portion, the MFR is 1.0 g / 10 min or less and a low fluidity material. Even if it exists, the discharge pressure Pe of a raw material will be 5.0 Mpa or less, and usually 1.0 Mpa or less. Then, the softened material with low fluidity is easily extruded in an indeterminate state without being molded. This state is shown as an irregular material m1 in FIG. In addition, if there are many compounding ratios of the filler in a raw material, the raw material m1 will be extruded with a powdery feeling, and if there are many compounding ratios of the resin in a raw material, the raw material m1 will be extruded in thick noodle shape. The above is the extrusion process.
The extruded amorphous material m1 is dropped and accommodated in the crusher hopper 32 and supplied into the crushing chamber 33. That is, the same material m1 is introduced into the introduction portion 31 while being indefinite.

The irregular shaped material m1 introduced into the introduction unit 31 is a material in which the resin is familiar with the filler, and the material having at least the filler familiar with the resin is pulverized and homogenized by the pulverizer 30. . The pulverized material m2 falls from the powder discharge port 37a and is accommodated in the molding machine container 23. The crushed material introduced into the pulverized material introduction part 24 is pushed in from the upper openings of the many through holes 23d by the push rollers 25, 25. In addition, since the raw material is pulverized, it is easy to enter the through hole 23d, and the amount of pellet forming per unit time is large. In addition, in the state of entering the through hole 23d, an appropriate void (a void that can be broken in the kneading step in which heat is applied from the forming material to the fired molded body) is generated between the particles of the material. The crushed material pushed into the through hole 23d is pushed out in a substantially rod shape from the lower opening of the through hole 23d. When the cutter 26b further rotates, the substantially rod-shaped material M4 is cut in the cross-sectional direction by the cutter 26b to have a length of 1 to 30 mm, and is formed into a pellet shape larger than the pulverized material particles.
The pellet-shaped molded material falls into the cooling tank 40 and is cooled and solidified. The generated pellets are collected from the cooling bath 40.
The above is the forming material generation step.

When the generated pellet m3 is charged as a raw material into the hopper 61 of the extrusion molding machine 60 shown in FIG. 11, it is pushed in the die direction while being mixed by the rotational operation of the screw 64 driven to rotate by the motor 65. At this time, since the heater 66 heats the pellet, the thermoplastic resin is melted and the pellet is softened. The softened material is pushed out from the die 63 and cut into a predetermined length by the cutter 67. Thereby, it shape | molds from the pellet to the shape of the molded object for baking, and the molded object for baking is manufactured by cooling a molded object. When the injection molding machine 70 shown in FIG. 12 is used, the softened material is pushed out from the die 63 and injected into the space between the molds 72 and 73. Thereby, it shape | molds from the pellet to the shape of the molded object for baking, and the molded object for baking is manufactured by cooling a molded object.
In the case where a lubricant is added to the material, since the slip between the fillers becomes good when the material for molding is molded into the shape of the molded body for firing, the material can be easily molded.
The above is the molding process.

When the formed molded body for firing M7 is placed in the furnace of the firing apparatus 80 shown in FIG. 13, the heat supply device 82 raises the temperature in the furnace to the firing temperature, so that the fired molded body is fired. The resin contained in the fired molded body is incinerated and removed during firing. Here, since the weight of the resin is not more than the weight of the filler, the degree of shrinkage from the fired molded body to the fired body is small. And if the inside of a furnace is cooled, a sintered body can be taken out from the inside of a furnace. Thereby, a fired body can be manufactured from the molded body for firing.
When the fibrous material is added to the material, the fired molded body is less likely to collapse, so that the fired body can be manufactured by forming a fired molded body having excellent shape retention.
The above is the firing step.
The fired body produced can be used as various ceramic products if the filler is an inorganic material, various metal products if the filler is a metal material, and various charcoal products if the filler is a wood-based material. is there.

  As described above, since the material including at least the filler and the resin is extruded in an indeterminate state and the extruded material is introduced into the introduction portion in an indefinite shape, the extrusion flow rate of the material is not limited. Therefore, even if the molten resin is a high-filler material with a low fluidity and less than the weight of the filler, it is possible to produce a large amount of molding material per unit time. It becomes possible to mass-produce the molded body for firing using the molding material. Further, since the fired molded body contains a resin, the fired molded body does not collapse during firing or before firing, and a fired molded body with good shape retention can be obtained. Furthermore, since the fired molded body is formed from a highly filled material, the degree of shrinkage from the fired molded body to the fired body is small.

Comparing the production method of the present invention with the conventional method of producing a fired product by forming a fired compact by press molding without adding anything to the finely divided inorganic material, the production method of the present invention is In addition, there is no collapse of the fired molded body before firing, and a useful effect that the shape retention of the fired molded body is sufficient is obtained. Note that if a pellet-shaped molding material is generated and molded into the shape of a fired molded body by extrusion molding or injection molding, it is no longer a batch-by-batch molding, reducing running costs, and reducing the cost of the fired molded body per unit time. A useful effect of improving the production amount can be obtained.
Comparing the production method of the present invention with the conventional method of manufacturing a fired body by adding water to a finely divided inorganic material and forming a fired compact by extrusion molding, the manufacturing method of the present invention By extruding in an indeterminate state and then forming a molding material and molding it into the shape of a molded body for firing, it becomes possible to mold a material that is less than the weight of the filler and highly filled with filler. In addition, the fired molded body is not greatly shrunk during firing, and it is possible to obtain a useful effect that the fired molded body can have a good shape retaining property and a fired body having a desired shape can be obtained. It is done. Further, by making the material highly filled, a useful effect that the degree of freedom of the shape of the fired molded body is improved and the shape of the fired body is improved is obtained.

Comparing the conventional surface treatment of the filler with the organosilane treatment reagent and the production method of the present invention, the production method of the present invention eliminates the need for surface treatment, reduces the running cost, unit A useful effect of improving the production amount of the molded body for firing per hour is obtained. Moreover, the silica component of the organosilane treatment reagent does not remain in the fired body, and a useful effect is obtained that a high-purity fired body can be obtained. Furthermore, by extruding the material in an indeterminate state, a molding material is generated and molded into the shape of a molded body for firing, so that the blending ratio of the resin is very small compared to the blending ratio of the filler. It is possible to form a material with a higher filler mixing ratio into the shape of a fired molded body, and to produce a fired body from such a highly filler-filled material. A useful effect is also obtained.
From the above, according to the production method of the present invention, it is possible to improve the production amount of the molded body for firing per unit time, and to form a fired molded body having excellent shape retention and to produce a high-quality fired body. A useful effect is obtained.

  In addition, once the amorphous material extruded by the extrusion mechanism is pulverized and formed into a pellet shape, the material can be formed into a pellet shape in a more uniform state. Thereby, a pellet can be homogenized more and it becomes possible to homogenize the molded object for baking and the sintered body. In addition, since the resin is well blended (compatibilized) with the filler, it is pelletized, so the pellet shape is maintained at the raw material stage when the pellet is formed into the shape of a fired molded body by extrusion molding or injection molding. On the other hand, in the kneading stage where heat is applied, the pellets are more easily broken and dispersed well. Therefore, it becomes easy to form from the pellets into the shape of the fired molded body. Furthermore, since the amorphous material is crushed, it becomes easier to enter molding holes and gaps when molding pellets, so that the amount of pellets generated per unit time can be further increased. It becomes possible to further increase the production amount of the fired body.

  In particular, if a material containing a high filling amount of a filler and a heat-softened thermoplastic resin is mixed and extruded (kneaded) without being crushed and formed into a pellet shape, the resin does not conform to the filler. Since it is pelletized, the filler and the resin are broken apart to form a pellet that tends to be powdered. Of course, if the thermoplastic resin is not softened, pellets that are more likely to collapse into powder are formed. In this case, when the pellet is used as a raw material to be molded into the shape of a molded body for firing, the pellet collapses into a powder form from the raw material stage, so that it is not easy to uniformly knead the raw material in the kneading stage. In the production method of the present invention, the melted resin and the filler are mixed and extruded as a softened material, and then pulverized and formed into a pellet shape. The pellet which does not collapse so as to become a shape is formed. Therefore, when the pellets are formed from the pellets into the fired molded body, the pellets are crushed and dispersed in the kneading stage where heat is applied without breaking into powder, so that the raw materials can be easily and uniformly kneaded in the kneading stage. it can.

  Furthermore, even if the blending ratio of the resin in the material is large and the conventional extruder is a material in which the pellets after molding are stuck together, the pellets after molding are not stuck to each other and separated. This is because, after extruding the softened material in an indeterminate state, it is not immediately molded into a pellet shape.Therefore, in the material blended with thermoplastic resin, due to the temperature drop, the material blended with thermosetting resin or adhesive This is because the degree of material softening is presumed to decrease with time. If the pellets are stuck together, the pellets are not smoothly fed into the molding process when the molded body for firing is produced. However, since the pellets are separated, the molded body for firing can be produced smoothly.

  If the resin M2 is a liquid synthetic resin, the first heating step for heating and melting the resin and the second heating step for heating and softening the molding material can be omitted. It can be lost. Thereby, the production amount of the molded object for baking per unit time can be increased, and the suitable structure which forms the molded object for baking excellent in shape retention property and can manufacture a sintered body can be provided. .

  In addition, when a fine particulate wood material is used as the filler M1, the wood material is carbonized by preventing the reaction with oxygen by firing the fired molded body in an inert gas not containing oxygen gas. A sintered body of carbon material can be produced. In this case, the firing temperature is preferably 550 to 2000 ° C, more preferably 800 to 1600 ° C. This is because a temperature of 550 ° C. (800 ° C.) or higher is preferable because the resin M2 can be surely incinerated and removed, and a temperature of 2000 ° C. (1600) ° C. or lower is preferable in terms of combustion efficiency. By using a wood-based material as the filler and firing the fired molded body in an inert gas atmosphere, a fired molded body of carbon material can be obtained using a resin, producing a fired molded body per unit time. It is possible to produce a high-quality carbon fired body by improving the amount and forming a fired molded body having excellent shape retention.

Actually, silica (SiO ₂ ) having a particle size of 0.1 to 100 μm and granular polypropylene (PP) having an MFR of 1000 (g / 10 min) under the condition M (test temperature 230 ° C.) in Appendix A Table 1 of JIS K7210 2 and FIG. 3 were used to form a flat plate shape, and a molded article of a fired molded body was produced as a prototype.

[Test Example 1]
A pellet M14 (molding material) is formed according to the manufacturing method of FIG. 2 with a silica mixing ratio of 80, 85, 90, 95% by weight and a PP mixing ratio of 20, 15, 10, 5% by weight. When a test for molding into the shape of a molded article for firing was performed using the extruder 60 with a heater shown in FIG. 11, in the test section of 80, 85, 90% by weight (PP 20, 15, 10% by weight) of silica. It was able to be formed into the shape of a molded body for firing without any problem. In the test group of 95% by weight of silica (PP 5% by weight), the extrusion flow rate per unit time was lower than that of 80, 85, 90% by weight of silica, but it was able to be molded into the shape of a fired molded body.

[Test Example 2]
A pellet M14 (molding material) is formed according to the manufacturing method of FIG. 2 with a blending ratio of silica in the material of 80, 85, 90% by weight and a blending ratio of PP of 20, 15, 10% by weight. When the test for molding into the shape of the fired molded body was performed with the illustrated injection molding machine 70 with a heater, the shape of the fired molded body was satisfactory in the test section of 80,85% by weight of silica (PP 20, 15% by weight). Was able to be molded. In the test section of 90 wt% silica (PP 10 wt%), the extrusion flow rate per unit time was lower than that of 80,85 wt% silica, but it could be formed into the shape of a fired molded body.

[Test Example 3]
The pulverized product M13 (molding material) is formed in accordance with the manufacturing method of FIG. Then, when a test for molding into the shape of a molded article for firing was performed with a press molding machine A40 with a heater, all test sections of silica 80, 85, 90, 95 wt% (PP 20, 15, 10.5 wt%) Thus, it was possible to form into the shape of a molded article for firing without any problem.

(4) Various modifications:
You may provide the container heating means which heats the said container for molding machines. When a heater is embedded in the molding machine container 23 and the heater is energized, the molding machine container 23 can be heated. Then, solidification by cooling of the amorphous material accommodated in the molding machine container 23 can be prevented, and the generation efficiency of pellets can be further improved.
A cutter heating means for heating the cutter may be provided. For example, when a heater is embedded in the cutter table 26a and the heater is energized, the cutter can be heated. Then, the raw material containing the thermoplastic resin can be softened in the vicinity of the cutter and easily cut, and the generation efficiency of pellets can be further improved.
When forming a pellet-shaped forming material, as disclosed in Japanese Patent Application Laid-Open No. 2004-17502, an amorphous material is rolled into a substantially flat plate shape with a pair of rolling rolls, and is shredded (resin shredder). It may be formed into a pellet shape by chopping.

As shown in FIG. 14, when a thermosetting resin M15 that is liquid (fluid state) at room temperature is used as the resin M2, in the extrusion step S1, the material is extruded in an indeterminate state without being heated by the extrusion mechanism A1. it can. Then, for example, the pellet M14 is formed in the forming material generation step S2, and in the forming step S3, the formed material is formed into the shape of the fired molded body by the forming mechanism A4, and then the formed material is formed by the third heating mechanism A6. When heated, the thermosetting resin in the material is cured and a strong fired molded body M7 can be formed. Then, the fired molded body is not collapsed during firing or before firing, and a fired molded body with very good shape retention can be obtained.
In addition, a curing agent or a curing accelerator for a thermosetting resin may be added when molding from a molding material such as the pellet M14 into the shape of a molded body for firing. Then, since the thermosetting resin in the raw material can be cured without heating the raw material for molding, a strong fired molding M7 can be formed. Then, the fired molded body is not collapsed during firing or before firing, and a fired molded body with very good shape retention can be obtained.

Furthermore, in the molding material generation step S2, the amorphous material M4 introduced into the introduction part A2 is at least pulverized by a pulverizing mechanism, and the pulverized material and the molten resin M2 have different physical properties. A molding material M6 may be formed by blending at least a second material having at least a resin. FIG. 1 shows that the second material M5 may be introduced into the introduction part A2 together with the irregular material M4.
When the forming material M6 is generated, as shown in the upper part of FIG. 15, at least the first amorphous material M4 and the second irregular material M21 are pulverized together by the pulverizing mechanism A12 and mixed. The molding material M6 such as the pellet M14 may be generated by generating M23, or after the materials M4 and M21 are separately pulverized by the pulverizing mechanisms A17 and A18 as shown in the upper part of FIG. The mixed first material (ground product M24) and the ground second material (ground product M25) may be mixed, for example, in the pellet forming mechanism A13 to generate the mixture M23.
In addition, as for the preferable mixture ratio of all the fillers and resin used in order to form the molded object for baking, the sum total of fillers is 51 to 99 weight% (more preferably 70 to 95 weight%), and the sum total of resin is 1. -49 wt% (more preferably 5-30 wt%).

When the two materials are mixed before pulverization, they are mixed by pulverizing the unshaped materials M4 and M21 together, which is preferable in that the mixing of both materials can be simplified. Of course, as shown in the lower part of FIG. 15, after mixing the irregular shaped materials M4 and M21 by a predetermined mixing mechanism A16 (mixing step S7), the mixture is pulverized by a predetermined pulverizing mechanism A12 (pulverizing step). S5) You may do it. Then, since the irregular first and second materials are reliably mixed, it is preferable in that the generated molding material can be more reliably homogenized.
When the irregular shaped materials M4 and M21 are pulverized together, the fourth material M22 may be pulverized together. If there is a fifth material, a sixth material, etc., these may be crushed together. In such a case, if the fourth material M22, the fifth material,... Are fine particles (powder or finer than pellets), they are easily mixed with the first and second materials of irregular shape. Therefore, it is preferable in that the generated molding material can be more reliably homogenized.
In order to make the molding material pulverized, the pellet forming step S6 of FIG. 15 may be omitted, and the pulverized mixture M23 may be used as the molding material M6.

When the first and second materials are mixed after pulverization, the familiarity of both materials can be reduced by separately pulverizing the irregular shaped materials M4 and M21. This is preferable in that the remaining high quality pellets can be manufactured. As shown in the lower part of FIG. 16, a pulverized product M24 is generated by a predetermined pulverization mechanism A17 (first pulverization step S8), and a pulverized product M25 is generated by a predetermined pulverization mechanism A18 (second pulverization step). S9) After mixing by the predetermined mixing mechanism A19 to generate the mixture M23 (mixing step S10), the mixture M23 may be formed into a pellet shape, for example (pellet forming step S6). Then, since the pulverized first and second materials are reliably mixed, it is preferable in that the generated molding material can be more reliably homogenized.
Note that when the pulverized products M24 and M25 are mixed, the fourth material M22 may be mixed together. If there is a fifth material, a sixth material, etc., these may be mixed together. In such a case, when the fourth material M22, the fifth material,... Are finely granular or low-viscosity (high fluidity) liquid (for example, MFR at the temperature when mixing is 100 or more) Since it is easy to be mixed with the pulverized first and second materials, it is preferable in that the generated molding material can be more reliably homogenized.
A single crushing mechanism may be shared by the crushing mechanisms A17 and A18.
In order to make the molding material pulverized, the pellet molding step S6 in FIG. 16 may be omitted, and the pulverized mixture M23 may be used as the molding material M6.

With the above configuration, in the molding material generation step S2, the amorphous material M4 introduced into the introduction part A2 is at least pulverized by a predetermined pulverization mechanism, and the pulverized material and the molten resin M2 have physical properties. And a second material having at least a second resin different from each other to form a molding material M6. In the molding step S3, a molding material M6 in which the pulverized material and the second material are blended at least. Is molded by the molding mechanism A4 to produce a fired molded body M7. Thereby, since the familiarity of several resin can be decreased when producing | generating the raw material for shaping | molding, the raw material for shaping | molding with which each physical property of each resin was left is generable. When this molding material is used as a raw material and molded into the shape of a fired molded body, each resin is heated and melted at the time of molding, and at this stage, the resins are familiar with each other to produce a fired molded body having a high-quality polymer blend, A fired body can be produced. When producing a pellet-shaped molding material, it is not necessary to mix pellets containing the first resin and pellets containing the second resin (and corresponding pellets if there are more resins) It becomes possible to obtain a high-quality fired molded body in which the resins are sufficiently blended together, and to obtain a high-quality fired body. In addition, by using a highly fluid resin, the fluidity can be made very good when molding from a molding material to a fired molded body.
In addition, by using the above-mentioned method, it contributes to the moldability of molding from a molding material to a fired molded body, but it may be modified or react with a resin or the like depending on the temperature conditions at the time of compounding (during mixing). It is also possible to use additives that would end up (for example, oil that is denatured at 200 ° C.).

  In addition, a thermosetting resin can be used for at least some of the plurality of types of resins. When both a thermoplastic resin and a thermosetting resin are used as the resin, a new polymer in which the thermoplastic resin and the thermosetting resin become compatible with each other at this stage when molding from a molding material to a molded article for firing is performed. A fired molded body having a blend can be produced, and a novel fired body can be produced.

As shown in FIG. 17, in the molding step S3, the molding material M6 is molded by the molding mechanism A4 to form the molded body M31 before the surface treatment, and the surface of the molded body M31 before the surface treatment is left leaving the filler M31a. After forming the surface-treated molded body M32 by removing at least the resin present in the surface, the suspension includes fine particles M34a made of an inorganic, metal, or wood-based material having an average particle size AR2 smaller than the average particle size AR1 of the filler M31a. The molded body for firing M33 may be manufactured by coating the surface of the surface-treated molded body M32 with the turbid liquid M34. When removing the resin, only the resin M2 may be removed, or a compatibilizing agent such as an acid-modified synthetic resin, a fibrous material such as a lubricant or a resin fiber, or the like may be removed.
As the filler M31a for forming the surface-treated molded body M32, the various fillers M1 described above can be used.
As the resin M2 for forming the surface-treated molded body M32, when removing the resin by heating the surface of the molded body M31 before the surface treatment, the above-described various resins can be used. In addition, when a resin that is deteriorated and removed by an acid, alkali, or organic solvent is used, an acid, an alkali, or an organic solvent is brought into contact with the surface of the molded body M31 before the surface treatment, thereby bringing the surface of the molded body M31 before the surface treatment. The existing resin M32 can be formed by removing the existing resin due to deterioration. Further, when a resin that is degraded and removed by ultraviolet rays is used, the surface of the molded body M31 before surface treatment is removed by degradation by irradiating the surface of the molded body M31 before surface treatment with ultraviolet rays. A processed molded body M32 can be formed.

As the fine particles M34a included in the suspension M34, the same material as the filler M1 described above can be used. The average particle size AR2 of the fine particles M34a is smaller than the average particle size AR1 of the filler M31a. The average particle diameter AR2 / AR1 of the fine particles relative to the average particle diameter of the filler may be 0 <AR2 / AR1 <1, for example, fine particles having an average particle diameter AR2 satisfying 0.001 <AR2 / AR1 <0.5 are used. be able to.
The liquid component M34b constituting the suspension M34 may be any liquid substance that allows the fine particles M34a to be suspended and coated on the surface of the surface-treated molded body M32, such as an organic solvent, a molten thermoplastic. Resins, liquid thermosetting resins, and the like can be used.
The mixing ratio of the fine particles M34a constituting the suspension M34 and the liquid component M34b may be any mixing ratio that imparts fluidity to the suspension M34. For example, the mixing ratio of the fine particles is 20 to 80% by weight, liquid The compounding ratio of the components can be 20 to 80% by weight.

  As a premise for producing the fired molded body M33 in this modification, first, a material containing a filler M33a and a liquid component M33b is mixed by an extrusion mechanism, extruded in an indeterminate state, and extruded from the extrusion mechanism. Is introduced into a predetermined introduction part in an indefinite shape, and a pellet-shaped forming material M6 is generated from the introduced indeterminate material. As the liquid component M33b, only a molten resin may be used, or a resin obtained by adding a compatibilizer such as an acid-modified synthetic resin, a lubricant, or the like to the molten resin. The material including the filler M33a and the liquid component M33b may include a fibrous material such as a resin fiber. The filler M33a may be obtained by reacting a finely divided inorganic material or metal material with a silane coupling agent.

When the forming material M6 is generated, the forming material M6 is formed into the same shape as the fired formed body M33 by the forming mechanism A4 to form the pre-surface-treated formed body M31 (upper stage in FIG. 17). Next, at least the resin present on the surface of the pre-surface-treated molded body M31 is removed while leaving the filler M31a to form the surface-treated molded body M32 (middle stage in FIG. 17). In the example of FIG. 17, a state in which the liquid component M31b on the surface has been removed is shown, and a state in which the filler M31a on the surface is exposed is shown. The surface from which the resin is removed may be one surface having the molded body before surface treatment, or may be a plurality of surfaces such as the entire surface of the molded body before surface treatment.
In the above state, the suspension M34 is coated (applied) on the surface of the surface-treated molded body M32 to form a fired molded body M33 (lower stage in FIG. 17). When the suspension M34 is coated so as to be covered with the fine particles M34a at least by the thickness from which the resin has been removed from the surface, the surface is smoothed by the fine particles M34a. Further, when the suspension M34 is coated so as to be covered with the fine particles M34a by the thickness of the average particle diameter AR1 of the filler M31a, the space between the fillers M33a can be filled with the fine particles M34a.

As described above, the fired molded body M33 can be manufactured.
Thereafter, when the fired molded body M33 is fired, a fired body can be manufactured. In the fired body to be formed, a filler M33a having a large particle diameter is present inside, while fine particles M34a having a small particle diameter are densely filled between the fillers M33a on the surface. Therefore, when a functional material that exhibits a useful function such as a catalyst is used for the fine particles M34a, a fired body that exhibits a useful function can be obtained without using a functional material for the filler M31a. Therefore, if an inexpensive material such as fly ash or slag is used as the filler and a functional material such as zirconia, zirconia silica, or a noble metal is used as the fine particles, a fired body having functionality can be manufactured at a low cost. .

  When mixing a material containing fine particulate filler and molten resin and extruding it in an indeterminate form, forming a molding material, and molding the molding material to produce a molded body for firing, the filler Since the fluidity of the material decreases as the particles become finer, the amount of the molded body for firing per unit time becomes smaller when using a small particle filler than when using a large particle filler. In this embodiment, a large amount of pre-surface-treated molded body M31 per unit time is formed using a filler of large particles, and then a surface-treated molded body M32 is formed to coat a suspension containing small fine particles. Thus, the molded body for firing M33 is formed, so that it is possible to mass-produce a useful molded body for firing in which a surface important for exhibiting a useful function is densely covered with small fine particles. In addition, since relatively small particles enter between relatively large fillers, a large number of particles prevent the fillers from being connected to each other. This makes it possible to produce a fired molded body and to produce a useful fired body. Furthermore, since the fine particles and the filler are in a close-packed state in the surface layer, there is little shrinkage when the fired molded body is fired, and a high-quality fired body can be obtained.

[Test Example 4]
As a filler, fly ash having a size of 10 to 100 μm (average particle size of 50 μm) was used. As a liquid component of the molded body before surface treatment, granular polypropylene (described as PP) having an MFR of 30 (g / 10 min) in condition M (test temperature 230 ° C., load 2.16 kg) in Annex A Table 1 of JIS K7210 Then, a maleic acid-modified resin (Yumex manufactured by Sanyo Kasei Co., Ltd.) obtained by modifying polypropylene with maleic acid was used.
As fine particles constituting the suspension, silica having 0.1 to 0.001 μm (average particle diameter of 0.01 μm) was used. MEK (Nissan Chemical Co., Ltd.) was used as a liquid component constituting the suspension.

A conical twin screw extruder (Titan 80 manufactured by Cincinnati Extrusion Co., Ltd.) having a diameter of 80 mm was used as a kneading extruder with a heater.
As a pulverizer, a wood grinder and a fine shredder manufactured by Inoue Electric Works were used.
Fly ash, PP, and maleic acid-modified resin are mixed into a kneading extruder with a heater, with a fly ash content of 90% by weight, a PP content of 8% by weight, and a maleic acid-modified resin content of 2% by weight. The raw material was heated to 230 ° C., mixed and extruded in an indeterminate shape and received by a hopper. The temperature of the raw material in the position of the exit in an extrusion mechanism was 180 degreeC. Then, the amorphous material received by the hopper was pulverized to a particle size of 1 mm or less by a pulverizer, and formed into a pellet shape having a diameter of 5 mm and a length of 5 mm by a pellet molding machine to produce a pellet.

The prepared pellets were put into a kneading extrusion molding machine with a heater for forming an extruded product having a cross section of 110 mm × 9 mm square. A molded body before surface treatment was made as a prototype.
Next, the surface of the pre-surface-treated molded body was sanded by heating to remove about 1 to 10 μm of the resin (including maleic acid-modified resin) existing on the surface, and a surface-treated molded body was made as a trial.
In addition, silica was added to liquid MEK and mixed to prepare a suspension. This suspension was applied to the surface of the surface-treated molded body, and MEK was volatilized to produce a sample of a molded body for firing.

  On the other hand, the suspension was applied to the surface of the molded body before the surface treatment, and MEK was volatilized to produce a sample of a molded body for firing.

For the sample of the test example and the sample of the comparative test example, an adhesion test (base peeling test) of the coating film by the cross-cut method specified in JIS K5600-5-6 is performed, respectively. The ratio of the area that did not adhere was determined. The results are shown in Table 1.

As shown in Table 1, in the sample of the comparative test example in which the resin existing on the surface was not removed, the coating film remaining rate was 54%, whereas in the sample of the test example in which the resin existing on the surface was removed, The coating film residual ratio decreased to 28%. Because of this, after removing the resin existing on the surface of the molded body before the surface treatment leaving the filler, coating the suspension on the surface of the surface-treated molded body, a large number of fine particles keep the fillers together. It is presumed that the surface layer containing fine particles is unlikely to peel off from the layer containing the filler in the fired molded article. Therefore, according to this modification, it is possible to mass-produce a useful fired molded body in which a surface important for exhibiting a useful function is densely covered with small fine particles, and it is possible to produce a useful fired body. It can be said that the effect becomes.
As described above, according to the present invention, according to various embodiments, the production amount of a molded body for firing per unit time is improved, and a high-quality fired molded body having excellent shape retention is formed to form a high-quality fired body. The body can be manufactured. Of course, there is also an invention in the fired body obtained by this production method, and it becomes possible to provide a fired body of good quality.

The schematic flowchart which shows the process in which the molded object for baking is manufactured and also a sintered body is manufactured. The schematic flowchart which shows the process in which the molded object for baking is manufactured using a thermoplastic resin. The schematic flowchart which shows the process in which the molded object for baking is manufactured using a thermoplastic resin. The external appearance side view of a pellet manufacturing apparatus. The external appearance top view of a pellet manufacturing apparatus. The perspective view which shows the principal part of a pellet shaping | molding apparatus. The vertical sectional view which shows the principal part of a pellet molding apparatus seeing from the B direction of FIG. The vertical sectional view which shows the principal part of a pellet molding apparatus seeing from the B direction of FIG. The perspective view which shows the modification of a grinding | pulverization mechanism. The top view which shows the bottom part disk of a shaping | molding mechanism seeing from an upper surface. The principal part side view which shows the structure of the extruder with a heater in partial cross section. The principal part sectional drawing which shows the structure of the injection molding machine with a heater. The principal part front view which shows the structure of a baking apparatus in partial cross section. The schematic flowchart which shows the process in which the molded object for baking is manufactured using a thermosetting resin in a modification. The general | schematic flowchart which shows the process in which an irregular-shaped raw material is grind | pulverized together and a mixture is produced | generated in a modification. The general | schematic flowchart which shows the process in which an irregular-shaped raw material is grind | pulverized separately in a modification, and a mixture is produced | generated. The schematic flowchart which shows the process in which the molded object for baking is manufactured in a modification.

Explanation of symbols

10 ... Pellet manufacturing equipment (molding material generation mechanism)
12 ... Material conveying device 13 ... Material heating device (first heating mechanism)
20 ... Pellet molding device (pellet molding mechanism)
30 ... Crusher (Crushing mechanism)
31, 50 ... Predetermined introduction portion 60 ... Extruder (having a forming mechanism)
70 ... Injection molding machine (with molding mechanism)
80: Firing device (firing mechanism)
A1 ... extrusion mechanism A2 ... predetermined introduction part A3 ... molding material generation mechanism A4 ... molding mechanism A5 ... firing mechanism A6 ... third heating mechanism A11 ... first heating mechanism A12 ... grinding mechanism A13 ... pellet molding mechanism A16, A19 ... mixing mechanism A17, A18 ... grinding mechanism A20 ... extrusion molding device A21 ... hopper A22 ... extruder A23 ... cutting machines A24, A31, A41 ... heating machine (second heating mechanism)
A30 ... Injection molding device A40 ... Press molding device M1 ... Fine particulate filler M2 ... Molten resin M3 ... Third material M4 ... Unshaped material M5 ... Second material M6 ... Molding materials M7, M33 ... Molded body for firing M8 ... fired body M11 ... thermoplastic resin M12 ... compatibilizers M13, M24, M25 ... pulverized product M14 ... pellet M15 ... liquid thermosetting resin M21 ... second material M22 of irregular shape ... fourth Material M23 ... mixture M31 ... molded body M32 ... surface treated molded article M34 ... suspension S1 ... extrusion step S2 ... molding material generation step S3 ... molding step S4 ... firing step S5 ... grinding step S6 ... pellet Molding step S7 ... Mixing step S8 ... First grinding step S9 ... Second grinding step S10 ... Mixing step

Claims (17)

Extrusion that extrudes in an indeterminate state by mixing at least a filler comprising a finely divided inorganic, metal, or wood-based material, and the filler and a resin in a fluid state equal to or less than an equal weight by an extrusion mechanism. Process,
A molding material that can be molded into a shape of a fired molded body for introducing a raw material extruded from the above extrusion mechanism into a predetermined introduction portion in an indefinite shape and firing to form a fired body. A molding material generation process for generating a material from an irregular material introduced into the introduction part,
And a molding step of manufacturing the formed molding material by the molding mechanism to manufacture a molded body for firing. In the molding material generation step, the amorphous material introduced into the introduction part is molded into a pellet shape to form the molding material,
2. The method for producing a fired molded body according to claim 1, wherein in the molding step, the pellet shaped molding material is molded by the molding mechanism to produce a fired molded body. 3.   In the molding material generation step, the amorphous material introduced into the introduction part is pulverized by a predetermined pulverization mechanism, and the pulverized material is formed into a pellet shape to form the molding material. The manufacturing method of the molded object for baking of Claim 2 to do. The molding mechanism is a mechanism for molding the molding material by extrusion molding or injection molding,
4. The firing according to claim 2, wherein in the molding step, the pellet-shaped molding material is molded by extrusion molding or injection molding with the molding mechanism to produce a fired molded body. 5. Method for forming a molded article. In the molding material generation step, the irregular material introduced into the introduction part is pulverized by a predetermined pulverization mechanism into the molding material,
2. The method for producing a fired molded body according to claim 1, wherein in the molding step, the ground molding material is molded by the molding mechanism to produce a fired molded body. The molding mechanism is a mechanism for molding the molding material by press molding,
6. The molded body for firing according to claim 5, wherein in the molding step, the molded material in the pulverized state is molded by press molding with the molding mechanism to produce a molded body for firing. Method. The resin is a thermoplastic resin,
The extruding step includes a first heating step in which a material including at least the filler and the thermoplastic resin is heated by a first heating mechanism to bring the thermoplastic resin into a molten state. The first heating step The material heated in is mixed in the extrusion mechanism and extruded in an indeterminate state,
The molding mechanism is a mechanism that mixes the molding material and extrudes it from a predetermined die and molds it into the shape of the molded body for firing,
The molding step includes a second heating step in which the molding material is heated and softened by a second heating mechanism, and the molding material softened in the second heating step is mixed by the molding mechanism. The method for producing a fired molded body according to claim 4, wherein the fired molded body is produced by extrusion from the die and molding.   The manufacturing method of the molded object for baking in any one of Claims 1-6 whose said resin is a liquid synthetic resin.   In the extrusion step, at least the filler, the fluidized resin, and a compatibilizer having compatibility with the resin and having a hydrophilic group are mixed by the extrusion mechanism to be indefinite. It extrudes in the state of this, The manufacturing method of the molded object for baking in any one of Claims 1-8 characterized by the above-mentioned.   The said compatibilizing agent is a synthetic resin obtained by adding a predetermined organic acid to a raw material of a synthetic resin compatible with the resin contained in the material, and synthesizing the resin. The manufacturing method of the molded object for baking of description.   In the extrusion step, at least the filler, the fluidized resin, and a resin molding lubricant are mixed in the extrusion mechanism and extruded in an indefinite state. The manufacturing method of the molded object for baking in any one of Claims 1-10.   2. The extrusion process, wherein a material including at least the filler, the resin in a fluid state, and a fibrous material is mixed by the extrusion mechanism and extruded in an indeterminate state. The manufacturing method of the molded object for baking in any one of Claims 11. A silane coupling step of obtaining a filler by reacting a finely divided inorganic material or metal material with a silane coupling agent;
In the extrusion step, at least the filler obtained in the silane coupling step and the fluidized resin are mixed by the extrusion mechanism and extruded in an indefinite state. The manufacturing method of the molded object for baking in any one of Claims 1-12. In the molding material generating step, the amorphous material introduced into the introduction part is at least pulverized by a predetermined pulverization mechanism, and the pulverized material and the resin in the fluid state are different from each other in the physical properties. A second material having at least
In the molding step, a molding material in which at least the pulverized material and the second material are blended is molded by the molding mechanism to produce a fired molded body. The manufacturing method of the molded object for baking of description.   In the molding step, the molding material is molded by the molding mechanism to form a molded body before surface treatment, and at least the resin existing on the surface of the molded body before surface treatment is removed leaving the filler. After forming the surface-treated molded body, the surface of the surface-treated molded body is coated with a suspension containing fine particles made of an inorganic, metal or wood-based material having an average particle size smaller than the average particle size of the filler. The said molded object for baking is manufactured, The manufacturing method of the molded object for firing in any one of Claims 1-14 characterized by the above-mentioned. Extrusion that extrudes in an indeterminate state by mixing at least a filler comprising a finely divided inorganic, metal, or wood-based material, and the filler and a resin in a fluid state equal to or less than an equal weight by an extrusion mechanism. Process,
A molding material that can be molded into a shape of a fired molded body for introducing a raw material extruded from the above extrusion mechanism into a predetermined introduction portion in an indefinite shape and firing to form a fired body. A molding material generation process for generating a material from an irregular material introduced into the introduction part,
A molding step of molding the generated molding material by the molding mechanism to form a fired molded body,
And a firing step of producing a fired body by firing the formed molded body for firing. At least a filler comprising a finely divided inorganic, metal, or wood-based material, and the filler and a resin in a fluid state equal to or less than the same weight are mixed in an extrusion mechanism and extruded in an indeterminate state.
A molding material that can be molded into a shape of a fired molded body for introducing a raw material extruded from the above extrusion mechanism into a predetermined introduction portion in an indefinite shape and firing to form a fired body. The material is generated from the irregular shaped material introduced in the introduction part,
The formed molding material is molded by the molding mechanism to form a fired molded body,
A fired body obtained by firing the formed fired compact.

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