JP5105493B2 - Molded simultaneously decorated fiber molded product and its manufacturing method - Google Patents

Description

  The present invention relates to a simultaneously molded decorative fiber molded product and a method for producing the same, and particularly relates to a molded simultaneous decorated fiber molded product capable of being beautifully decorated and a method for manufacturing the same.

  Conventionally, as a method for producing a fiber molded article, a mixture obtained by adding a polymer binder and water to a fibrous main material and kneading is used as a molding material, and the molding material is filled in a cavity of a heated mold, A gap of 0.02 to 0.50 mm is formed between the parting surfaces of the mold, and water vapor generated in the cavity is discharged and removed from the gap to dry and solidify the molding material, thereby forming a fiber. There has been a method of manufacturing a decorative fiber molded product for obtaining a product (see, for example, Patent Documents 1 and 2).

  Since pulp is frequently used as the fibrous main material used in the production method, the production method of the above-mentioned fiber molded article is also called pulp injection molding (PIM (registered trademark)).

Japanese Patent No. 2916136 Japanese Patent No. 3084216

  The conventional fiber molded article as described above has a problem that it is difficult to perform beautiful decoration.

  That is, in order to decorate the fiber molded product, means such as a screen printing method can be used for the fiber molded product, but the fiber molded product must have a flat shape, and the application range is greatly limited. Moreover, although a fiber molded article can be decorated by coloring a molding material, it can only be made into the single color of the whole fiber molded article, and cannot be said to be a beautiful decoration.

  Therefore, it is conceivable to perform a beautiful decoration on the plastic sheet in advance, and insert it in a mold for manufacturing the fiber molded product in advance, and form it integrally with the fiber molded product. Such a decoration method can be used to pre-decorate a plastic sheet to form beautiful designs and the like, and can be integrated on the surface of a three-dimensional molded product. Often used for decoration, it is also called insert molding method or simultaneous molding method.

  However, since the decoration method uses a plastic sheet, the moisture contained in the molding material cannot be released to the outside as water vapor in the drying step in the manufacturing method of the fiber molded product. It was difficult to apply.

  In addition, it is conceivable to use a non-woven fabric having good water vapor transmission instead of the plastic sheet, but the drying process in the method for producing a fiber molded product is longer at a higher temperature than the method for producing a plastic molded product. Because it is heated for a period of time, the nonwoven fabric melts due to the heat applied in the drying process and is still difficult to apply.

  The present invention has been made in order to solve the above-described problems, and an object of the present invention is to provide a molded and simultaneously decorated fiber molded product that can be beautifully decorated and a method for manufacturing the same.

  In order to achieve the above object, according to a first invention, a pattern is previously formed and decorated on an easy-molding paper in which a fine ridge is formed on one side and an apparent size is reduced, and the easy-molding paper is molded as a mold. The mixture is then clamped, then a mixture obtained by adding a polymer binder and water to the fibrous main material and kneading is used as the molding material, and the molding material is filled into the cavity of the heated mold, and then the mold A gap of 0.02 to 0.50 mm is formed between the parting surfaces, and water vapor generated in the cavity is released and removed from the gap to dry and solidify the molding material. This is a method of manufacturing a simultaneously molded decorative fiber molded product to obtain a fiber molded product in which a sheet is integrally formed on the surface.

  If comprised in this way, an easily moldable paper will become what was integrated with the fiber molded product.

  2nd invention is the structure of 1st invention, The easily formed paper in which the pattern was formed is preformed by the solid | 3D shape so that the said cavity surface shape of a metal mold | die may be formed, Molding simultaneous decorating fiber It is a manufacturing method of a molded article.

  If comprised in this way, an easily moldable sheet | seat will closely follow a cavity surface within a metal mold | die.

  3rd invention is the structure of 1st invention, After mold opening, the said easily formed paper unnecessary along the surrounding shape of the said fiber molded product is removed, The manufacturing method of a simultaneous molding decorative fiber molded product is there.

  If comprised in this way, an unnecessary part will be removed and beautiful shaping | molding simultaneous decoration will be attained.

  As described above, according to the first invention, the easy-forming paper is integrated with the fiber molded product, and water vapor is properly removed from the mold in the heat drying process, but the design of the easy-forming paper is not impaired. Simultaneous decoration is possible. Moreover, since there are few restrictions of a decoration means, various expressions are attained.

  In the second invention, in addition to the effects of the first invention, since the mold surface is exactly along the cavity surface, the molding material does not turn around, and the simultaneous decoration of the three-dimensional shape can be more reliably performed. Become.

  In addition to the effects of the first invention, the third invention removes unnecessary portions, so that simultaneous molding with a beautiful peripheral shape of the molded product becomes possible.

It is sectional drawing which shows an example of the easily formed paper used for this invention. It is a photograph which shows an example of the fine wrinkle formed on the one surface of the easily-formed paper used for this invention. It is sectional drawing which shows one Example of this invention. It is sectional drawing which shows one Example of this invention. It is sectional drawing which shows one Example of this invention. It is a perspective view which shows one Example of this invention.

  Next, a first embodiment of the present invention will be described with reference to the drawings.

  The manufacturing method of the simultaneously molded decorative fiber molded product 7 according to the present invention is such that a pattern 2 is formed in advance on a readily formable paper 1 formed with fine wrinkles on one side and having a small apparent size. A mixture obtained by sandwiching in a mold, then clamping and then adding a polymer binder and water to a fibrous main material and kneading is used as the molding material 5, and the molding material 5 is filled into a cavity of a heated mold. Next, a gap of 0.02 to 0.50 mm is formed between the parting surfaces of the mold, and water vapor generated in the cavity is released and removed from the gap to dry and solidify the molding material 5; Next, the mold is opened to obtain a fiber molded product 6 in which the easy-forming paper 1 is integrally formed on the surface.

  First, a pattern 2 is formed and decorated in advance on an easily-molded paper 1 having a fine ridge formed on one side and an apparent size reduced (see FIG. 1).

  As the easy-molding paper 1, a paper having fine wrinkles formed on one side and having a reduced apparent size is used (see FIG. 2). Since the easy-forming paper 1 having such a configuration is excellent in three-dimensional formability, it can be laminated beautifully without causing wrinkles or tearing when it is integrally laminated on the surface of the fiber molded product 6 having a three-dimensional shape. Is possible. Moreover, in the drying process performed later, the water vapor permeability is excellent. Further, the paper itself is not deteriorated by heating applied in the drying process.

  More specifically, the easily formed paper 1 may be obtained by the following manufacturing method. That is, a wet paper whose water content in the paper is adjusted to 20 to 50% is applied to the circumference of the metal roll using a shrinkage imparting device consisting of a metal roll having a groove in the circumferential direction at regular intervals in the width direction of the roll and a smooth rubber roll. The breaking elongation in the longitudinal direction and the transverse direction is 15 to 50% by passing the paper through a shrinkage imparting device composed of a press roll whose peripheral speed of the rubber roll is slower than the speed, and shrinking the web, and drying after the treatment. Easy formable paper 1 can be obtained (see Japanese Patent No. 3407114, etc.).

  The natural pulp used as the raw material of the easily-formed paper 1 is not particularly limited as long as it is a normal papermaking raw material such as wood pulp using conifers and hardwoods, non-wood pulp such as kenaf and bagasse, and waste paper pulp. From the viewpoint of versatility, use of wood pulp is preferred. The beating degree of this wood pulp is preferably CSF 200 to 450 ml, more preferably CSF 250 to 400 ml, from the viewpoint of elongation characteristics, strength, papermaking properties and the like. The blending ratio of natural pulp is preferably 50% or more.

  On the easily formed paper 1 having such a configuration, a pattern 2 is formed and decorated by means of various printing methods. As the printing method, means such as a relief printing method, an intaglio printing method, a lithographic printing method, and a stencil printing method can be used. Further, the pattern 2 may be formed by means that does not use a plate such as an ink jet printing method. As the ink for forming the pattern 2, a dye or a pigment may be used as a coloring material. The pattern 2 may be formed so as to be laminated as an ink layer on the easily formed paper 1. Further, the pattern 2 may be formed by impregnating the fibers constituting the easily-formed paper 1 with ink.

  In addition, when reusing or disposing of the simultaneously molded decorative fiber molded product 7 by using a material derived from a natural material or a biodegradable material as an ink coloring material or binder, it is environmentally friendly. It becomes possible to make it easier.

  Next, the easy-forming paper 1 is sandwiched between the molds 3 and then the molds are clamped (see FIG. 3).

  The mold 3 can be injected with a molding material 5 used to obtain a fiber molded product 6, and pulp injection molding is configured to discharge and remove moisture contained in the molding material 5 as water vapor by heating. Those used in the law are used (see Japanese Patent No. 2916136, Japanese Patent No. 3084216, etc.).

  In order to ensure that the easy-forming paper 1 follows the cavity surface of the mold 3, the easy-forming paper 1 may be three-dimensionally formed in advance into the shape of the cavity surface (preliminary molding). Three-dimensional molding may be performed by a known means such as a press method. By arranging the easy-forming paper 1 along the cavity surface, in the subsequent filling step of the molding material 5, the molding material 5 wraps around the surface of the easy-forming paper 1 that is finally located on the outermost surface ( Can also be prevented.

  Next, a mixture obtained by adding a polymer binder and water to the fibrous main material and kneading is used as the molding material 5, and the molding material 5 is filled into the cavity 4 of the heated mold 3 (see FIG. 4).

  As the fibrous main material, wood pulp using conifers and hardwoods, non-wood pulps such as kenaf and bagasse, waste paper pulp, and other ordinary papermaking raw materials can be used. In addition, any of natural fibers such as paper waste, waste paper, cotton cloth, hemp, rice husk, tofu husk, wood flour, and glass fiber and fibers made of synthetic resin such as nylon, polyacryl, polyester, etc. Although usable, paper fibers such as paper waste and waste paper are particularly preferable. In addition, since the fiber length of such a paper fiber is short, in the case of a molded product requiring strength, it is effective to combine other fibers with 5% to 40%, preferably 5% to 20%. The length of the composite fiber is preferably 3 mm to 10 mm.

  As a polymer binder, when kneaded with a fibrous main material, a water-soluble or low-viscosity emulsion is formed, and when water is vaporized and removed, the molded product is separated in a solid form. Those that are easy to mold are preferred, and water-soluble polymer materials such as starch, polyvinyl alcohol, polyacrylic acid, polyacrylamide, polyitaconic acid, carboxymethylcellulose, and copolymers thereof can be used, and urea resins, Even thermosetting resins that are not inherently water-soluble, such as melamine resins, phenol resins, and unsaturated polyesters, whose initial condensates are aqueous solutions or emulsions can be used.

  A mixture obtained by adding and kneading the above-described polymer binder and water to the above-described fibrous main material is referred to as a molding material 5. The blending ratio of the molding material 5 is, for example, 50% to 90% for the fibrous main material, preferably 60% to 80%, 10% to 50% for the polymer binder, preferably 20% to 40%, and water. 20% to 80%, preferably 30% to 70%.

  The mold 3 may be heated, for example, so that the temperature of the mold wall surface forming the cavity 4 is 120 ° C. to 240 ° C., preferably 160 ° C. to 220 ° C.

  Next, a gap of 0.02 to 0.50 mm is formed between the parting surfaces of the mold 3, and water vapor generated in the cavity 4 is discharged and removed from the gap to dry and solidify the molding material 5. Let

  By filling the molding material 5 into the cavity 4 of the heated mold 3, the water added at the time of kneading is instantly vaporized, and the fibrous main material is foamed by the vapor pressure. At the same time, the fibrous main material is vaporized. Since the cavity 4 is filled with pressure and pressed against the wall surface, even a molded product having a large change in thickness is molded with good transferability, and vaporized water vapor is exhausted and removed from the gap between the molds 3. The molded product is quickly solidified. Since the easily formed paper 1 is excellent in air permeability, it does not hinder the discharge of water vapor in the drying process. Moreover, since the easily-formed paper 1 is formed from a material having excellent heat resistance such as pulp, it does not cause alteration such as melting or yellowing by heating in the drying process.

  Next, the mold can be opened to obtain a simultaneously molded decorative fiber molded product 7 in which the easily molded paper 1 is integrally formed on the surface of the fiber molded product 6 (see FIG. 5).

  Finally, if necessary, an unnecessary area of the easily formed paper 1 around the fiber molded product 6 is removed by means such as a press method or a Thomson method, whereby a beautiful molded simultaneous decorated fiber molded product 7 can be obtained. Yes (see FIG. 6).

  The molded co-decorated fiber molded article 7 thus obtained has no surface difference between the area in contact with the cavity surface of the fiber molded article 6 and the area in contact with the cavity surface of the easy-formed paper 1, and the surface is surface. It will be excellent in a sense of unity. Moreover, since the fiber molded product 6 and the easily-formed sheet 1 are firmly adhered by hydrogen bonding, they can be integrated without using an adhesive or the like. Further, the easy-forming paper 1 and the fiber molded product 6 are both formed from a fibrous material such as pulp, and the touch is unique and soft. Furthermore, since both are reused and discarded, they are formed from a fibrous material such as pulp, so that it becomes an environmentally friendly product that is extremely easy to process.

  A pattern was formed on one side of an easily-formed paper (Cartiere Cariolaro) made of 100% pulp and having fine wrinkles formed on one side using an inkjet printer. This easy-molding paper was previously press-formed into a molded product shape and formed into a three-dimensional shape along the cavity surface of the mold.

  Also, hemp and mulberry were used as the fibrous main materials, starch was used as the polymer binder, and water was added and kneaded to obtain a molding material.

  The easy-forming paper was fixed to the cavity surface of a pulp injection mold heated to 155 to 170 ° C., and the mold was clamped to fill the molding material. Next, a 0.20 mm gap was formed on the parting surface of the mold, and the molding material was dried and solidified by discharging and removing water vapor for 1 to 2 minutes.

  Then, the mold was opened to obtain a fiber molded product in which easy-molding paper was integrated, and the peripheral shape of the easy-molded paper was punched and removed with a Thomson mold to obtain a simultaneously molded decorative fiber molded product.

  The molded simultaneous decorated fiber molded article thus obtained was a beautifully decorated three-dimensional shape. The easy-forming paper was free from wrinkles and tears, and the easy-forming paper and the fiber-molded product were firmly integrated, and there were no steps at the joints, and they were beautiful.

  The present invention relates to a simultaneously molded decorative fiber molded product and a method for producing the same, and particularly relates to a molded simultaneous decorated fiber molded product capable of being beautifully decorated and a method for manufacturing the same.

DESCRIPTION OF SYMBOLS 1 Easy-molding paper 2 Design 3 Mold 4 Cavity 5 Molding material 6 Textile molded article 7 Molding simultaneous decoration textile molded article

Claims (3)

A pattern is formed and decorated in advance on easy-molded paper with a fine ridge formed on one side and the apparent dimensions reduced.
The easy-forming paper is sandwiched between molds,
Next, mold clamping
Next, a mixture obtained by adding a polymer binder and water to a fibrous main material and kneading is used as a molding material, and the molding material is filled into a cavity of a heated mold,
Next, a gap of 0.02 to 0.50 mm is formed between the parting surfaces of the mold, and water vapor generated in the cavity is released and removed from the gap to dry and solidify the molding material.
Next, the mold is opened to obtain a fiber molded product in which the easily molded paper is integrally molded on the surface thereof.   The method for producing a simultaneously molded decorative fiber molded product according to claim 1, wherein the easily-formed paper on which the design is formed is preformed into a three-dimensional shape along the shape of the cavity surface of the mold.   The method for producing a simultaneously molded decorative fiber molded article according to claim 1, wherein after the mold is opened, the unnecessary easy-forming paper is removed along the peripheral shape of the fiber molded article.

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