JP5247642B2 - Manufacturing method of plant fiber heat insulating mat - Google Patents

Description

  The present invention relates to a method for producing a heat insulating mat of plant fiber type (pulp fiber (including recycled pulp fiber), wood fiber, hemp fiber, bamboo fiber, etc.).

  The materials used for conventional heat insulating materials are mainly foamed resin-based and mineral fiber-based heat insulating materials made from petroleum. The construction method of the foamed resin heat insulating material is a construction method such as a spraying method, a filling method, or an extrusion mat molding. The construction method of the mineral fiber-based heat insulating material is mainly a mat-like construction method.

JP2008-127872 JP2007-230228 JP 2000-160713 A

However, the following problems occur in the foamed resin-based and mineral fiber-based heat insulating materials using petroleum as a raw material.
Problems with the destruction of the global environment due to the use of chlorofluorocarbon gas during the construction of foamed resin insulations Problems with the generation of harmful gases in the event of fires with foamed resin insulations Problems with concerns about the occurrence of dust (house dust, etc.) in mineral fiber insulations Of environmental damage due to increased CO2 emissions during production of heat-insulating materials and mineral fibers

In order to solve the above-mentioned problems, it is conceivable to use plant fibers such as pulp fibers (including recycled pulp fibers that are recycled by recycling newspaper residual paper and the like into cotton and fibers).
However, the main application field of plant fiber has been mainly used as a heat insulating material for buildings.
Moreover, there were three main construction methods for plant fibers: spraying method, blowing method, and filling method.
Accordingly, the present inventor has invented a technique for molding plant fibers into mats and felts (hereinafter abbreviated as mats) in order to expand the application range of plant fibers as heat insulating materials, thereby expanding the market. Aim to apply to.
In addition, the method of constructing the mat of the vegetable fiber heat insulating material of the present invention includes two methods, a wet method and a dry method.

By inventing a technique for forming plant fibers into a mat shape, the scope of application as a heat insulating material has been expanded, and it has become possible to propose a heat insulation method for new fields other than the construction field. For example, it can be applied as a heat insulating material for transport refrigeration containers, non-combustible sections for office buildings, clean rooms, home appliances, automobiles, and the like.
Accordingly, an object of the present invention is to realize a next-generation heat insulation method using plant fibers in consideration of energy saving and fire safety problems of buildings.

  In order to achieve the above object, a method for producing a heat insulating mat made of vegetable fiber according to the present invention includes a step of placing a first face material having flexibility and air permeability on a bottom wall having air permeability of a mold. A first plant fiber layer is formed by laminating a predetermined weight of plant fibers on the first face material together with an adhesive so that the height on the first face material is uniform. A step of forming, a step of placing a flexible and breathable second face material on the first plant fiber layer, and a predetermined weight on the second face material. A step of laminating plant fibers together with an adhesive so that the height on the second face material is uniform to form a second plant fiber layer, and by such a step on the bottom wall of the mold Forming a laminate in which a plurality of plant fiber layers are laminated together, and compressing the plant fiber layers each time the plant fiber layers are formed. A step of compressing the laminate, a step of bringing the laminate into a drying oven while maintaining a constant thickness on the bottom wall of the mold, and drying, and after drying, the mold is removed. And obtaining a vegetable fiber heat insulating mat.

According to the production method of the present invention, a plant fiber heat insulating mat is obtained in which plant fibers are entangled with a face material and the plant fiber layer is difficult to peel off, and the obtained plant fiber heat insulating mat is excellent in handleability. .
Therefore, according to the production method of the present invention, since a heat insulating mat made of vegetable fiber excellent in handleability can be obtained, the application range as a heat insulating material made of vegetable fiber is expanded, and a new field other than the building field is applied. Application to the heat insulation method is possible, and the following effects are produced.
Do not use chlorofluorocarbon for construction of plant fiber insulation (non-fluorocarbon method).
The plant fiber heat insulating material subjected to the flameproofing treatment has a performance as an incombustible material or a flame retardant material, and does not generate harmful gas in the event of a fire.
In the case of using recycled pulp fiber among plant fibers, recycled pulp fiber is mainly made of newspaper and other used paper again in fiber form and cotton form. Insulating material (recycled material).
There is little dust generation like mineral fiber system.
In other words, various heat insulation methods using a heat insulating mat made of vegetable fiber having high added value with high technological innovation in consideration of environmental problems and fire safety are possible.

It is a perspective view of a formwork. It is a perspective view in the state where the 1st face material was mounted in the bottom wall of a formwork. It is a perspective view of the state which attached the cover to the formwork. It is sectional drawing of the state which formed the 1st pulp fiber layer on the 1st face material. It is sectional drawing of the state which mounted the 2nd face material on the 1st pulp fiber layer. It is sectional drawing of the state which formed the 2nd pulp fiber layer on the 2nd face material. It is sectional drawing of the state which formed the laminated body which consists of a 1st thru | or 4th pulp fiber layer on the bottom wall of a formwork. It is a perspective view in the state where a compression iron plate was placed on a layered product. It is sectional drawing of the state which mounted the iron plate for compression on the laminated body. It is a perspective view of the state where the upper lid was placed on the compressed layered product. It is sectional drawing of the state which mounted the upper cover on the compressed laminated body. It is explanatory drawing which attracts | sucks the air of the obstruction | occlusion space inside a cover board through a vacuum pump and a hose at the time of spraying of a pulp fiber. It is a perspective view of a heat insulating mat made of pulp fibers. It is a perspective view of a heat insulating mat made of pulp fibers.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
In the present embodiment, a case will be described in which pulp fibers are used among plant fibers such as pulp fibers (including recycled pulp fibers), wood fibers, hemp fibers, bamboo fibers and the like.
First, as shown in FIG. 1, a rectangular bottom wall 12 having air permeability, a pair of side walls 14 rising from two opposite sides (long sides) of the bottom wall, and two opposite sides of the bottom wall. A mold 16 is provided that has a pair of end face walls 15 that stand up from (short sides) and connect both ends of the pair of side walls 14 in the longitudinal direction.
For example, as shown in FIG. 4, the bottom wall 12 includes a steel lattice body 18 in which steel bars are assembled in a lattice shape, a punching metal 20 placed on the lattice body 18, and a punching metal 20. And the mesh sheet 22 placed on the top.
By making the bottom wall 12 have such a breathable structure, it is possible to improve the sprayability of pulp fibers, which will be described later, and to facilitate the passage of hot air in a drying furnace, which will be described later, and to increase the drying efficiency. ing.
In the present embodiment, the short side of the bottom wall 12 is 600 mm, and the long side is 1200 mm.
The side wall 14 and the end surface wall 15 are made of a steel plate, and the height of the side wall 14 and the end surface wall 15 from the upper surface of the bottom wall 12 is larger than the thickness of the pulp fiber heat insulating mat to be obtained.

Next, as shown in FIG. 2, on the entire bottom wall 12, that is, on the bottom walls 12 inside the pair of side walls 14 and the pair of end face walls 15, the first flexible and breathable first is provided. A face material M1 is placed.
As such a face material M1, nonwoven fabrics and nets made of various conventionally known materials such as synthetic resin fibers and glass fibers can be used.

Next, as shown in FIG. 3, a cover 24 having four side portions is installed so as to be positioned on an extension above the pair of side walls 14 and the pair of end surface walls 15.
This cover 24 can suppress scattering of dust at the time of spraying pulp fibers, which will be described later, and is advantageous in improving the working environment.
The cover 24 may be made of wood or made of synthetic resin.

Next, pulp fibers having a predetermined weight are made uniform on the first face material M1 on the first face material M1 inside the pair of side walls 14 and the pair of end face walls 15, and the height on the first face material M1 becomes uniform. Thus, the first pulp fiber layer (first plant fiber layer) S1 is formed by spraying (laminating) with the adhesive.
In addition, formation of the 1st pulp fiber layer (1st plant fiber layer) S1 may level the upper surface so that it may become uniform height after spraying a pulp fiber.
The spraying may be performed manually using a spray gun, a pump, or the like, or may be performed automatically using a spray gun, a pump, a robot, or the like.
In the present embodiment, the discharge amount is adjusted so that the density of the pulp fiber is 20 to 100 kg / m ³ .

  In this case, as shown in FIG. 12, a plate 2602 having a hole at a position corresponding to the bottom wall 12, a leg portion 2604 that supports the plate 2602, and the plate 2602 and the legs 2604 are attached to the periphery. A base 26 having a cover plate 2606 is provided. Then, the mold 16 is placed so as to cover the hole on the plate 2602, and when the pulp fiber is sprayed, the air in the closed space inside the cover plate 2606 is sucked through the vacuum pump and the hose 2608. It is possible to suppress dust scattering when the pulp fiber is sprayed, which is advantageous in improving the working environment. Further, it is advantageous for uniformly laminating the pulp fibers and for intertwining the pulp fibers with the first face material M1.

Commercially available products can be used as the pulp fibers to be sprayed. For example, the trade name “Dunpack” manufactured by Oji Bags Co., Ltd. can be used.
In the case of the wet method, the pulp fiber and the adhesive are sprayed at the same time, or the material obtained by mixing the pulp fiber with the adhesive in advance is sprayed with the water.
The adhesive is preferably a water-based adhesive or a water-soluble adhesive.
In the case of the dry construction method, a material obtained by previously mixing an adhesive with pulp fibers is sprayed.
The adhesive is preferably heat-meltable.

Next, when the first pulp fiber layer S1 is formed in this way, as shown in FIG. 5, a second face material having flexibility and air permeability over the entire area of the first pulp fiber layer S1. Mount M2.
The material of the second face material M2 is the same as that of the first face material M1.

Next, as shown in FIG. 6, pulp fibers having a predetermined weight are placed on the second face material M2 on the second face material M2 inside the pair of side walls 14 and the pair of end face walls 15. The second pulp fiber layer (second plant fiber layer) S2 is formed by spraying so as to be uniform in height.
In this case as well, the formation of the second pulp fiber layer S2 may level the upper surface so as to have a uniform height after the pulp fibers are sprayed.
Further, when the pulp fibers are sprayed, air in the closed space inside the cover plate 2606 is sucked to improve the working environment, to uniformly laminate the pulp fibers, and to remove the pulp fibers. This is advantageous when entangled with the first face material M1.
Here, in this embodiment, the predetermined weight is the same as the weight of spraying when forming the first pulp fiber layer S1.
The second pulp fiber layer S2 is formed with the same thickness as the first pulp fiber layer S1.
The spraying may be performed manually as described above, or may be performed automatically.
The pulp fiber and adhesive used are the same as described above.

In the present embodiment, by such a procedure, as shown in FIG. 7, the third and fourth pulp fiber layers (third and fourth plant fiber layers) using the third and fourth face materials M4. S3 and S4 are formed to form a laminate 30 in which four pulp fiber layers (plant fiber layers) are laminated.
Here, the materials of the third and fourth face materials M3 and M4 are the same as those of the first and second face materials M1 and M2.
The spray weight for forming the third and fourth pulp fiber layers S3 and S4 is the same as that of the first and second pulp fiber layers S1 and S2, and the third and fourth pulp fibers. The thicknesses of the layers S3 and S4 are the same as those of the first and second pulp fiber layers S1 and S2.
Of course, the thicknesses of the first to fourth pulp fiber layers S1 to S4 may be set to different values, but they are formed with the same thickness as in this embodiment. If this is done, it is advantageous for achieving uniform heat insulating performance over the entire surface, and also for the design.
The spraying may be performed manually as described above, or may be performed automatically. The pulp fibers and adhesive used for spraying the third and fourth pulp fiber layers S3 and S4 are the above-mentioned It is the same.
Further, when the pulp fibers are sprayed, air in the closed space inside the cover plate 2606 is sucked to improve the working environment, to uniformly laminate the pulp fibers, and to remove the pulp fibers. This is advantageous when entangled with the first face material M1.

Next, as shown in FIGS. 8 and 9, the cover 24 is removed and the iron plate 32 for compression is placed on the laminated body 30, and the iron plate 32 is kept in a parallel state with respect to the bottom wall 12 while maintaining the bottom. In the present embodiment, the laminated body 30 is compressed until the thickness reaches a predetermined thickness close to the wall 12 until the laminated body 30 has a predetermined thickness.
The compression iron plate 32 includes a flat plate portion 3202 and a rectangular plate-shaped insertion portion 3204 that protrudes downward from the lower surface of the flat plate portion 3202 and is inserted into the side wall 14.
In this case, as shown in FIG. 8, a base 34 with guide rods 3402 protruding from four corners is prepared.
A stopper 3404 is screwed into each guide rod 3402 so as to have the same height from the base 34.
In addition, insertion holes 3206 through which the guide rod 3402 is inserted are formed at the four corners of the flat plate portion 3202.
Then, the mold 16 on which the laminated body 30 is formed is placed, the guide rods 3402 are respectively inserted into the insertion holes 3206 at the four corners, and a plurality of weights are placed on the laminated body 30. 32 insertion portions 3204 are placed.

Thereby, the iron plate 32 descends while compressing the laminated body 30 as time passes, and eventually comes into contact with the stopper 3404.
If the flat plate portion 3202 comes into contact with the stopper 3404, the four stoppers 3404 are lowered by an equal amount, and further, the iron plate 32 is lowered over time to compress the laminate 30.
Thus, the position of the stopper 3404 is adjusted, and the laminate 30 is compressed by the iron plate 32 a plurality of times to obtain a desired thickness. In this embodiment, the thickness of the laminate 30 is set to 100 mm by four times of compression. .
If the compression is performed a plurality of times in this manner until the laminated body 30 has a desired thickness, it is advantageous to perform the compression uniformly over the entire area of the bottom wall 12.
This compression is performed every time the pulp fiber layers S1, S2, S3, S4 are formed, for example, so that each pulp fiber layer S1, S2, S3, S4 has a thickness of 25 mm (predetermined). May be. Thus, if it compresses whenever it forms each pulp fiber layer S1, S2, S3, S4, it will become advantageous when ensuring the flatness of face material M2, M3, M4.

When the laminate 30 reaches a desired thickness, the iron plate 32 is removed, and an air-permeable upper lid 36 is placed on the upper surface of the laminate 30 as shown in FIGS. 10 and 11, and the upper lid 36 is molded. Attached to the frame 16 using a jig or the like as appropriate. The thickness of the laminated body 30 is kept constant by the upper lid 36 and the mold 16.
The configuration of the upper lid 36 is the same as the configuration in which the bottom wall 12 is turned upside down. The steel lattice body 18 that is positioned at the uppermost position and has steel bars assembled in a lattice shape is provided below the lattice body 18. The punch metal 20 is provided, and the mesh sheet 22 is provided below the punching metal 20.
By providing the upper lid 36 with air permeability, hot air can easily pass through a drying furnace, which will be described later, and the drying efficiency is improved.

And the laminated body 30 hold | maintained with the formwork 16 and the upper cover 36 is carried in to a drying furnace, and is dried with the hot air using a hot air machine.
After drying, the mold 16 and the upper lid 36 are removed, and a pulp fiber heat insulating mat (plant fiber heat insulating mat) 40 shown in FIG. 13 is obtained.
Note that various types of conventionally known dryers can be used to dry the laminate 30.

According to the production method of the present invention, when the pulp fiber is sprayed, the bottom wall 12 and the face material have air permeability, so that the spraying operation is efficiently performed, and at the same time, the pulp fiber easily entangles with the face material together with the adhesive. .
Therefore, the pulp fibers are intertwined with the first to fourth face materials M1, M2, M3, and M4, and the pulp fiber layer has a structure that does not easily peel off, so that the pulp fiber heat-insulating mat 40 excellent in handleability can be obtained.
The obtained heat insulating mat 40 made of pulp fibers may be used by cutting the outer peripheral portion or appropriate portions so as to have a desired shape.
Alternatively, as shown by an imaginary line A in FIG. 13, the obtained pulp fiber heat insulating mat 40 is cut into a strip shape with a width of, for example, 100 mm to form a long heat insulating mat piece 40A, as shown in FIG. Alternatively, the direction of the heat insulating mat pieces 40A may be changed by 90 degrees, and the left and right surfaces may be bonded with an adhesive to form a pulp fiber heat insulating mat 40. The heat insulating mat 40 made of pulp fibers made of the heat insulating mat piece 40A is excellent in strength and thermal conductivity.
The obtained heat insulating mat 40 made of pulp fibers can also be used as a soundproof mat.

In the present embodiment, the case where the pulp fibers are sprayed when forming the first, second, third, and fourth pulp fiber layers S1, S2, S3, and S4 has been described. A plurality of molds 16 are placed on the transport line, and the pulp fibers heat-insulating mat 40 is mass-produced from above the transported molds 16 by dropping and stacking them uniformly from the stirrer without spraying the pulp fibers. It may be.
Further, in the case of manufacturing a long heat insulating mat made of pulp fiber, the formwork 16 only needs to have a bottom wall 12 and a pair of side walls 14 rising from the bottom wall. It becomes unnecessary. In this case, after drying, the mold 16 and the upper lid 36 are removed, and then the pulp fiber heat insulating mat 40 corresponding to both ends in the longitudinal direction of the pair of side walls 14 is cut to a predetermined size. do it.
Further, depending on the application, it is optional to subject the pulp fiber heat insulating mat 40 to a flameproof treatment.
Moreover, the number of the pulp fiber layers which comprise the pulp fiber heat-insulating mat 40 is arbitrary.
In the present embodiment, the case where pulp fibers are used as plant fibers has been described. However, the present invention can be widely applied to other plant fibers such as wood fibers, hemp fibers, bamboo fibers, and the like.

  12 ... Bottom wall, 14 ... Side wall, 16 ... Formwork, 32 ... Steel plate for compression, 30 ... Laminate, 36 ... Top lid 36, M1 ... First face material, M2 ... First 2 face material, M3 ... 3rd face material, M4 ... 4th face material, S1 ... 1st pulp fiber layer, S2 ... 2nd pulp fiber layer, S3 ... 3rd pulp Fiber layer, S4 ... Fourth pulp fiber layer.

Claims (7)

Placing the first face material having flexibility and breathability on the breathable bottom wall of the mold; and
A first plant fiber layer is formed by laminating a predetermined weight of plant fiber with an adhesive on the first face material so that the height on the first face material is uniform. And a process of
Placing a second face material having flexibility and breathability on the first plant fiber layer;
A second plant fiber layer is formed by laminating a predetermined weight of vegetable fiber together with an adhesive on the second face material so that the height on the second face material is uniform. And a process of
A step of forming a laminate in which a plurality of plant fiber layers are laminated on the bottom wall of the mold by such a step;
Compressing the plant fiber layer every time the plant fiber layer is formed, or compressing the laminate;
A step of bringing the laminate on the bottom wall of the formwork into a drying oven while maintaining a constant thickness, and drying the laminate;
After drying, removing the mold and obtaining a vegetable fiber heat insulating mat;
A process for producing a heat insulating mat made of vegetable fiber, comprising: Maintaining the thickness of the laminate in the drying step is performed by placing an air permeable upper lid on the laminate and attaching the upper lid to the mold.
The method for producing a heat insulating mat made of vegetable fiber according to claim 1. A closed space is provided between the bottom wall and the bottom wall;
When the plant fibers are laminated, the air in the enclosed space is sucked.
The method for producing a heat insulating mat made of vegetable fibers according to claim 1 or 2. The mold has a pair of side walls standing upright from two opposite positions of the bottom wall,
The placement of the first face material and the formation of the first and second plant fiber layers are performed inside the pair of side walls.
The method for producing a heat insulating mat made of vegetable fibers according to any one of claims 1 to 3. After the drying, after removing the formwork, cut the plant fiber heat insulating mat corresponding to both ends in the longitudinal direction of the pair of side walls,
The method for producing a heat insulating mat made of vegetable fiber according to claim 4. The mold frame has a pair of side walls standing upright from two opposite positions of the bottom wall and a pair of end face walls standing up from two opposite positions of the bottom wall and connecting both longitudinal ends of the pair of side walls. Have
The placement of the first face material and the formation of the first and second plant fiber layers are performed inside the pair of side walls and the pair of end face walls.
The method for producing a heat insulating mat made of vegetable fibers according to any one of claims 1 to 3. The plurality of plant fiber layers, the plant fibers are laminated with the same thickness,
The method for producing a heat insulating mat made of vegetable fibers according to any one of claims 1 to 6.

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