JP5955415B2 - Bamboo powder-containing molded body, vehicle interior material and building material, and method for producing bamboo powder-containing molded body - Google Patents

Description

  The present invention relates to a bamboo powder-containing molded body, a vehicle interior material and a building material, and a method for producing a bamboo powder-containing molded body.

  In order to consider the global environment and effectively use plants, various members formed by blending plant-derived powders as part of the raw materials have been proposed. For example, tray containers using bamboo as part of raw materials, synthetic boards, and pneumatic tires have been proposed (see Japanese Patent Application Laid-Open Nos. 2005-329688, 2008-030380, and 2011-012110). ).

When bamboo is used as a part of the raw material of the molded body, generally, fiberized in the fiber direction of the vascular bundle (longitudinal direction of bamboo) or carbonized and powdered bamboo is used. Yes.
If bamboo is fiberized in the fiber direction of the vascular bundle, the effect of increasing the strength can be obtained, but a large amount of energy is required for fibrosis. In addition, when bamboo fiber is used, there is a risk of occurrence of poultry.

  On the other hand, the strength effect is hardly obtained with bamboo powder obtained by carbonizing bamboo into powder. Also, for example, when blending a powdery body obtained by grinding bamboo with a binder, a large amount of energy is required for extrusion and injection molding.

  The present invention provides a bamboo powder-containing molded article that can be produced with less energy, is safe, and provides air permeability control and strength effects, a method for producing the same, a vehicle interior material and a building material using the same. The purpose is to provide.

In order to achieve the above object, the following invention is provided.
According to the 1st side surface of this invention, the bamboo powder containing molded object containing the scaly bamboo powder which has the hole derived from a vascular bundle is provided.
The scaly bamboo powder is preferably layered in the thickness direction, and preferably contains a binder.

According to the second aspect of the present invention, the sheet-like material containing the scaly bamboo powder is prepared by a papermaking method using a scaly bamboo powder having pores derived from the vascular bundle and water. There is provided a method for producing a bamboo powder-containing molded body comprising a sheet-shaped material forming step to be formed and a primary molding step in which moisture is removed from the sheet-shaped material to form a primary molded body.
The bamboo powder dispersion preferably further contains a binder. Further, the method may further include a secondary molding step in which the primary molded body is hot-pressed to form a secondary molded body.

  ADVANTAGE OF THE INVENTION According to the present invention, a bamboo powder-containing molded body that can be manufactured with less energy, is safe, and can provide air permeability control and strength effects, a method for manufacturing the same, a vehicle interior material and a building using the same Materials are provided.

It is the schematic which shows an example of the method of manufacturing scaly bamboo powder. It is the image which showed the scaly bamboo powder which has the hole originating in a vascular bundle. It is the schematic which shows an example of the manufacturing process of the bamboo powder containing molded object which concerns on this invention. It is an image which shows an example of the molded object (primary molded object) in which the scaly bamboo powder piled up in layers by the papermaking method. It is the image which showed the bamboo powder obtained by grinding bamboo.

  Hereinafter, the bamboo powder-containing molded article and the method for producing the same according to the present invention will be specifically described.

<Bamboo powder-containing molded body>
The bamboo powder-containing molded body according to the present invention (suitably referred to as “molded body”) is a scaly bamboo powder having pores derived from vascular bundles (appropriately “scaled bamboo powder” or simply “bamboo powder”). And a binder as a reinforcing material in addition to the scale-like bamboo powder. Hereinafter, the components of the bamboo powder-containing molded body according to the present invention will be described.

(Scaly bamboo powder)
The bamboo powder contained in the molded body of the present invention has a scale shape (thin plate shape, scale shape, and Flake shape), and has pores derived from the vascular bundle in the thickness direction. The scale-like bamboo powder used in the present invention has a thickness of preferably 100 to 1000 μm, more preferably 300 to 600 μm, and a diameter (width) when viewed in plan is preferably 50 to 3000 μm. More preferably, it is 100-800 micrometers.

  The scaly bamboo powder used in the present invention can be obtained by cutting bamboo in the direction intersecting with the fibers, preferably cutting (slicing) at a substantially right angle to the bamboo vascular bundle. For example, as shown in FIG. 1, the direction of the vascular bundle of the bamboo 12 (longitudinal direction) is rotated while rotating the cutting means 10 in which a plurality of circular saw blades are stacked and pressing the end face of the bamboo against the cutting means 10. ). As a result, the vascular bundle extending in the longitudinal direction of the bamboo 12 is cut vertically, and as shown in FIG. 2, scaly bamboo powder having holes derived from the vascular bundle can be continuously produced. According to such a method, bamboo can be made into powder regardless of the age of the bamboo, and it is also possible to cut and process bamboo cut out from bamboo bamboo, etc., so that it can be processed once with less energy Thus, for example, scaly bamboo powder having a size of about 500 μm can be efficiently obtained.

  As a cutting means for producing the scale-like bamboo powder used in the present invention, for example, a bamboo powder production apparatus described in JP-A-2003-236403 can be used. As a commercial item, for example, Marudai Iron Works Co., Ltd. bamboo powder manufacturing machine “PANDA” can be used.

What is necessary is just to determine content of the scale-like bamboo powder contained in the molded object of this invention according to the use etc. of a molded object. The strength, air permeability, weight and the like of the molded body can be adjusted by the content of the scale-like bamboo powder. For example, the greater the content of scale-like bamboo powder, the higher the air permeability.
Although the form with which scale-like bamboo powder is mix | blended in the molded object of this invention is not specifically limited, It is preferable that it overlaps with the layer shape in the thickness direction. The scaly bamboo powder is laminated to form an integrated state, which provides a strength effect. The laminated scaly bamboo powder has holes that penetrate in the thickness direction. It can be set as the molded object which has.

  As described above, when cutting (slicing) at a substantially right angle to the bamboo vascular bundle, the cutting powder is usually all scaly bamboo powder, but some bamboo powder other than scaly may be mixed in. There is also. A mixture of bamboo powder other than scaly may be used, but 90% by mass or more of the bamboo powder used is preferably scaly bamboo powder.

(binder)
The binder is mainly used to reinforce the strength of the molded body, but by adding the binder, the density and breathability can be adjusted in addition to the strength of the molded body, and the degree of freedom in design can be increased. .

  As a binder that can be used in the present invention, it is easy to mold by mixing with scaly bamboo powder, the strength of the molded body can be improved, and the temperature at which bamboo does not deteriorate (depending on the molding time). For example, what can be processed at 250 ° C. or lower) may be used. For example, a fibrous or particulate organic material combined with scale-like bamboo powder is preferable. Specific examples include thermoplastic fibers, natural fibers including pulp, and thermosetting powder.

Examples of the thermoplastic resin that can be used as the binder include polyvinyl: acrylonitrile-butadiene-styrene resin, polyvinyl chloride, polystyrene, polyvinylidene chloride, polyvinylidene fluoride, polyvinyl acetate, polyolefins: polypropylene, polyethylene, and polyester. System: acrylic resin, polyethylene terephthalate, polyamide system: polyamide 6, 11, 12, thermoplastic polyurethane system, and the like may be used, and a fibrous material having a coating layer such as a thermoplastic resin or a thermoplastic elastomer may be used.
The fiber length of the fibrous material is preferably 0.5 to 20 mm, more preferably 1 to 5 mm, and the fiber diameter is preferably 10 to 300 μm, more preferably 20 to 200 μm.

Moreover, as a thermosetting resin which can be used as a binder, a phenol resin, a melamine resin, an epoxy resin, an unsaturated polyester resin, etc. are mentioned.
The particle size of the powdery material used as the binder is preferably 5 to 20 μm, more preferably 2 to 10 μm.

What is necessary is just to determine the content of the binder in the molded object of this invention according to the use etc. of a molded object. When high strength is not required, the molded body may be composed of scaly bamboo powder without containing a binder. However, by adding a binder, it is easy to mold and the strength can be increased.
When the molded body of the present invention is a hard board that can be used as, for example, a vehicle interior material or a building material, the content of the binder in the molded body may be 5% by mass or more in order to ensure strength. Preferably, it is more preferably 10% by mass or more. On the other hand, in order to ensure air permeability, the content of scaly bamboo powder in the molded body is preferably 65% by mass or more, and more preferably 80% by mass or more.
The ratio (mass ratio) between the content of the scale-like bamboo powder and the content of the binder in the molded body is preferably 90:10 to 65:35, more preferably 80:20 to 70:30. .

(Other ingredients)
The molded article of the present invention may contain other components in consideration of the properties required for the molded article and the ease of production of the molded article. For example, flame retardants, density adjusting agents (fillers), dispersants, Examples include antifoaming agents.

<Method for producing bamboo powder-containing molded body>
Although the method for producing the bamboo powder-containing molded product of the present invention is not particularly limited, it can be suitably produced using a papermaking method. That is, the method for producing a bamboo powder-containing molded body of the present invention uses a scaly bamboo powder having pores derived from vascular bundles and a bamboo powder dispersion containing water, and includes the scaly bamboo powder by a papermaking method. A sheet-like material forming step for forming the sheet-like material, and a primary molding step for removing water (dehydration and drying) from the sheet-like material to obtain a primary molded body. Moreover, when setting it as molded objects other than a sheet form, or when raising an intensity | strength, the secondary shaping | molding process which hot-presses a primary molded object and makes it a secondary molded object can further be included.

  Hereinafter, each process of the manufacturing method of the bamboo powder containing molded object of this invention is demonstrated. FIG. 3 schematically shows an example of a method for producing a bamboo powder-containing molded body according to the present invention.

(Sheet formation process)
First, a sheet-like material containing the flaky bamboo powder is formed by a papermaking method using a flaky bamboo powder having pores derived from the vascular bundle and a bamboo powder dispersion containing water.

Bamboo powder dispersion liquid is obtained by adding and mixing water after cutting scaly bamboo powder or by drying (absolutely dry condition: for example, drying at 115 ° C. for 1 hour or more). Can do. The mixing ratio of water and bamboo powder is only required to maintain a state in which scaly bamboo powder is dispersed in water. For example, 0.1 to 10 parts by mass of bamboo powder is added to 100 parts by mass of water. . In order to keep the scale-like bamboo powder stably dispersed in water, a surfactant may be added to the bamboo powder dispersion.
The bamboo powder dispersion preferably contains the above-described binder (matrix) in order to improve the strength of the molded article to be produced. The blending ratio (mass basis) of the scaly bamboo powder and the binder may be determined according to the intended use of the molded article.
Furthermore, you may add other components, such as a flame retardant, according to the use of the target molded object.

The bamboo powder dispersion is stirred and mixed in the container (FIG. 3 (A)), and the scaly bamboo powder is poured by a papermaking method to form a sheet-like material containing the scaly bamboo powder (FIG. 3 (B)). .
Papermaking is a technique for producing Japanese paper, and when producing paper, a method of scooping fibers from a dispersion containing water or a method of filtering fibers from water is used. . Although broadly divided into hand-making and machine-making, any of the present invention can be applied.

By forming a sheet-like material by papermaking using a dispersion containing scaly bamboo powder as a raw material, a sheet-like material in which scaly bamboo powder is layered in the thickness direction can be obtained. Since the sheet-like material is formed by a papermaking method using water as a medium, the production energy is small and a large-sized sheet-like material can be formed.
In addition, according to the papermaking method, a sheet-like material can be produced with a small amount of binder (matrix), and in particular, the scaly bamboo powder and the fibrous binder are entangled well, whereby the strength is remarkably improved.
The basis weight may be determined according to the strength and density required of the molded body, but is preferably 0.2 g / cm ³ or more in order to obtain the strength as the molded body.

In the paper making in the present invention, for example, a hand machine may be used for batch use, or a continuous machine may be used for long use. As a hand-drawing machine, for example, the printing Chao-kai “New measuring machine for papermaking and printing” p. 178-179 (2002), "TAPPI type handrail machine", "square sheet machine", etc. can be used. Also, as a continuous machine, CMC publication “Development of functional nonwoven fabric” p. “Inclined wire type long net (short net) paper machine” and “circular net paper machine” described in 232-233 (2004) can be used.
Further, without using a paper machine, for example, after a bamboo powder-containing dispersion is stirred and mixed in a cylindrical container, the bamboo powder is allowed to settle and sieved with a filter to obtain a sheet-like material.

(Primary molding process)
After forming a sheet-like material containing scaly bamboo powder by a papermaking method, moisture is removed from the sheet-like material to obtain a primary molded body.
For example, the sheet-like material 30 containing scaly bamboo powder is taken out from the inside of the container (FIG. 3C), compressed from both sides by the press 22 and dehydrated (FIG. 3D). When moisture remains in the sheet-like material after dehydration, it is preferable to dry it and evaporate the remaining moisture. When dehydrating by pressing from both sides of the sheet-like material, it may be heated and dried together with the press.
The drying means is not particularly limited, and for example, warm air or hot air may be applied, it may be heated by a heater, left in a high temperature or low humidity drying chamber, or may be naturally dried. .
The primary molded body 31 can be obtained by removing moisture from a sheet-like material containing scaly bamboo powder formed by papermaking (FIG. 3E).
FIG. 4 shows the formed body after the primary forming step, and scale-like bamboo powder is layered in the thickness direction.

(Secondary molding process)
The sheet-like material from which moisture has been removed can be used as a primary molded body. However, when the strength is further increased, or when a molded body other than a sheet is to be formed, the primary molded body 31 is hot-pressed to obtain a secondary body. It can be set as the molded body 32 (FIG. 3F).
After dehydration and drying, it is put into a predetermined mold and compression-molded by hot pressing, whereby the strength can be increased and the desired shape can be formed. In the case of performing the secondary molding step, from the viewpoint of improving molding ease and strength, the bamboo powder dispersion is preliminarily containing a binder, preferably a thermoplastic resin, more preferably a thermoplastic fibrous binder. It is preferable to form a sheet-like material containing bamboo powder and a binder.

  The conditions (temperature, pressure, time, etc.) in the secondary molding step may be determined according to the form of the molded article to be produced, the type of binder, the blending amount of the binder, etc. The hot press conditions in the secondary molding step are: What is necessary is just to determine according to melting | fusing point of a binder, fluidity | liquidity, etc. For example, when a thermoplastic binder is included, it can be compressed with a mold after heating.

Through the above steps, a secondary molded body 32 containing scaly bamboo powder and a binder can be obtained. In the above method, for example, a large board can be manufactured in order to obtain a sheet-like material by a papermaking method. In addition, what is necessary is just to determine the shape of a secondary molded object according to a use.
The bamboo powder-containing molded product of the present invention can be obtained by making a sheet by a papermaking method using water as a medium as described above, and can be produced by drying, compression, etc. A close molded body can be obtained.

In addition, in the present invention, since a molded body is produced using scaly bamboo powder having holes in the thickness direction, air permeability can be increased, and compared with the case where powdered bamboo powder is simply used. Bending strength can be increased. For example, secondary molding having the following air permeability, bending strength, plate thickness, and density by containing scaly bamboo powder in an amount of 65% by mass to 99% by mass and a binder in an amount of 1% by mass to 35% by mass. The body can be manufactured.
Air permeability: 0.05 (cm ³ / cm ² / sec.) Or more Bending strength: 10 (MPa) or more Plate thickness: 0.5 (mm) or more Density: 0.2 (g / cm ³ ) or more

  Examples will be described below, but the present invention is not limited to these examples. In the following description, unless otherwise specified, “part” and “%” relating to the blending amount (content, addition amount) are based on mass.

<Example 1>
-Preparation of bamboo powder dispersion-
Using bamboo powder manufacturing machine “PANDA” manufactured by Marudai Iron Works Co., Ltd., bamboo was cut (sliced) at right angles to the vascular bundle to obtain scaly bamboo powder (cut powder). The average thickness of the bamboo powder was 400 μm and the average width was 600 μm.

  The obtained scaly bamboo powder and thermoplastic binder fiber (material: polypropylene, size: 2.4 dtex × 5 mm) were blended in water. Specifically, the blending ratio (mass ratio) between the scale-like bamboo powder and the thermoplastic binder fiber is bamboo powder: thermoplastic PP (polypropylene) binder fiber = 80: 20, and with respect to 1000 parts by mass of water. Then, 8.3 parts by mass (dilution rate: 120 times) of the bamboo powder and fibers were mixed with stirring to obtain a bamboo powder dispersion A1.

-Sheet formation process-
A sheet-like material A1 was produced by a papermaking method using the bamboo powder dispersion A1 as follows.
A dispersion containing 250 g of bamboo powder and fibers in 30 L of water (dilution rate: 120 times) is stirred with a stirrer for 1 minute, transferred to a vessel with a 250 mesh, filtered (dehydrated), and then evacuated. The time was about 30 seconds.

-Molding process-
The remaining sheet (bamboo powder + fiber) A1 was taken out of the container and dehydrated with a dehydration press (3 MPa, 2 minutes). It was dried at 110 ° C. for 4 hours to obtain a primary molded body.
After drying, it was molded by a hot press machine. The hot press conditions were 160 ° C., 5 minutes, and 5 MPa. This obtained the molded object A1 of Example 1. FIG.

<Example 2>
-Sheet formation process-
In the preparation of the bamboo powder dispersion A1 of Example 1, the blending ratio (mass ratio) between the scale-like bamboo powder and the thermoplastic binder fiber was changed to bamboo powder: thermoplastic binder fiber = 70: 30. A bamboo powder dispersion A2 was prepared in the same manner as in Example 1, and a sheet-like material A2 was prepared by a papermaking method in the same manner as in Example 1 using the bamboo powder dispersion A2.

-Molding process-
In the molding step of Example 1, the hot press conditions were the same, and a molded body A2 was produced.

<Comparative Example 1>
-Preparation of bamboo powder dispersion-
Using a stone mill grinder, the bamboo was ground to obtain a ground bamboo powder (ground powder). FIG. 5 shows the ground powder.
A bamboo powder dispersion B1 was prepared in the same manner as in Example 1 except that the above ground powder was used as the bamboo powder.

-Sheet formation process-
In the sheet-like material forming step of Example 1, sheet-like material B1 was produced by a papermaking method in the same manner as in Example 1 except that bamboo powder dispersion B1 was used instead of bamboo powder dispersion A1.

-Molding process-
In the molding step of Example 1, a molded body B1 was produced in the same manner as in the molding step of Example 1, except that the sheet B1 was used instead of the sheet A1.

<Example 3>
-Sheet formation process-
Using the bamboo powder dispersion A1 of Example 1, a sheet A3 was produced by the papermaking method in the same manner as in Example 1.
-Molding process-
Using the sheet-like material A3, a molded body A3 was produced in the same manner as in Example 1 except that in the molding step of Example 1, the pressure of the hot press was changed to 15 MPa.

<Example 4>
-Sheet formation process-
Using the bamboo powder dispersion A2 of Example 2, a sheet A4 was produced by the papermaking method in the same manner as in Example 1.
-Molding process-
Using the sheet-like material A4, a molded body A4 was produced in the same manner as in Example 1 except that in the molding step of Example 1, the pressure of the hot press was changed to 15 MPa.

<Comparative example 2>
-Sheet formation process-
In the sheet-like material forming step of Example 1, the same as Example 1 except that bamboo powder dispersion B2 (ground bamboo powder: PP binder fiber = 70: 30) was used instead of bamboo powder dispersion A1. Thus, a sheet-like material B2 was produced by a papermaking method.
-Molding process-
In the molding step of Example 1, a molded body B2 was produced in the same manner as in the molding step of Example 1 except that the sheet B2 was used instead of the sheet A1.

[Evaluation]
The following evaluation was performed about the molded object obtained by the Example and the comparative example.

(Bending strength)
The bending strength of the molded body was measured according to JIS A5905 by the following method.

(density)
The density was determined from the weight and volume of the molded body.

(Air permeability)
The air permeability of the molded body was measured according to JIS 1096-A.

  Table 1 summarizes the raw materials, hot press conditions, and evaluation results of the compacts produced in the examples and comparative examples.

  As shown in Table 1, in the example using scale-like bamboo powder, it turns out that bending strength and air permeability are high compared with the case where bamboo powder other than scale-like is used.

  The present invention can be implemented with various modifications without departing from the scope of the invention. Needless to say, the scope of rights of the present invention is not limited to the above embodiments.

  The bamboo powder-containing molded body according to the present invention is a molded body including scaly bamboo powder and a binder, so that it is a vehicle interior material (for example, a back board), a building material (for example, a wall surface material for an acoustic room). Etc.), but is not limited thereto. For example, if it is a molded body in which the content of scaly bamboo powder is increased, it can also be applied to filters, buffer materials, deodorizing agents, and the like.

Claims (8)

  A bamboo powder-containing molded article containing scaly bamboo powder having pores derived from a vascular bundle.   The bamboo powder-containing molded article according to claim 1, wherein the scaly bamboo powder is layered in the thickness direction.   Furthermore, the bamboo-powder containing molded object of Claim 1 or Claim 2 containing a binder.   The vehicle interior material which consists of a bamboo-powder containing molded object as described in any one of Claims 1-3.   The building material which consists of a bamboo-powder containing molded object as described in any one of Claims 1-3. Using a bamboo powder dispersion containing flaky bamboo powder having water derived from vascular bundles and water, a sheet-like material forming step of forming a sheet-like material containing the flaky bamboo powder by a papermaking method;
A primary molding step of removing moisture from the sheet to obtain a primary molded body;
The manufacturing method of the bamboo powder containing molded object containing this.   The method for producing a molded body according to claim 6, wherein the bamboo powder dispersion further contains a binder.   The method for producing a bamboo powder-containing molded body according to claim 6 or 7, further comprising a secondary molding step in which the primary molded body is hot pressed to form a secondary molded body.