JPH05214700A - Incombustible molded product and its production - Google Patents

Abstract

PURPOSE:To obtain the subject molded product having incombustibility and water resistance, capable of being massively produced, and useful as a wall material, etc., by immersing a mold having a paper-making screen in a slurry consisting mainly of sepiolite, vacuum-sucking the slurry to form a paper layer on the screen, demolding the formed paper, dehydrating and drying the molded product. CONSTITUTION:The production of the objective incombustible molded product 10 having incombustibility and water resistance comprises producing a slurry 1 containing sepiolite as a main material and further containing methylaminoethyl methacrylate polymer, etc., as a strong cationic polymer and an acrylamide/acrylic acid copolymer, etc., as a strong anionic polymer in a total amount of 0.2-1.0wt.% based on the solid content of the raw materials, charging the produced slurry 1 in a slurry tank 2, immersing a molding device 3 having a screening mold 5 formed of a screening net in the slurry 1, subjecting the main body 4 of the molding device 3 to a vacuum suction using a vacuum pump 8, demolding the molded paper layer 9 formed on the screening mold 5, dehydrating the molded product and subsequently drying the molded product.

Description

Detailed Description of the Invention

[0001]

The present invention relates to a pipe, a pipe such as an elbow and the like, a wall covering material having an uneven surface, which is formed into a wet sheet (paper) state by using a forming die in a slurry and dried and solidified. Related to non-combustible molded products used as building materials, household paper products, crafts such as reliefs, and the manufacturing method thereof, in particular, not only non-combustible but also water resistant, and can be mass-produced at a low price. The present invention relates to a nonflammable molded product and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, there is a sheet molded product obtained by pressing a paper sheet or the like in a wet state against a mold or the like at room temperature. The sheet molded product is easy to handle and inexpensive.
Moreover, due to its characteristics such as being lightweight and giving a unique feel,
It is used not only for household paper products such as plates and cups, but also for crafts such as reliefs, as well as industrial products such as packing, filters and sheet heat exchangers. However, these sheet molded products are flammable and easily broken, and when they are not subjected to a special treatment on the surface, they have defects such as lack of water resistance.

Therefore, asbestos fiber paper is usually used when flame retardancy and heat resistance are required. However, asbestos has recently become unusable in Japan due to its harmful effects on health. In Western Europe, it is almost unusable. From this situation, with the development of new materials, the development of alternative materials similar to asbestos is being actively researched in various places, and high-performance inorganic fibers or whiskers are being developed one after another. However, in the present situation, these fibers have not reached the level of substitutes for asbestos in terms of use, productivity, price, etc.

In addition, there is a flameproofing method as a method for producing a sheet molding which is difficult to burn. This is a method found in wallpaper, shoji paper, paper heat exchangers, etc., and can be said to be a treatment method that does not ignite. The base material is one in which wood pulp paper such as kraft paper is impregnated or coated with a flameproofing agent, and an ammonium salt-containing aqueous inorganic salt, a phosphorus-containing nitrogen compound, a phosphorus-containing halogen compound, an antimony trioxide-halogen compound, a boron compound, A halogen compound or the like is used. However, this treatment is mainly organic matter after all and cannot be said to be completely nonflammable. Aromatic polyamide fibers are also used as high-performance fibers, but they are not widely used.

Under these circumstances, attention has been paid to the possibility of using sepiolite as an alternative to asbestos among existing natural fiber products. There are also many cases of non-combustible sheets that use sepiolite.

Sepiolite is a clay mineral commonly referred to as mountain leather, mountain cork and mountain wood, and sepiolite in Japan is also a kind of this. The appearance may be cork-like, leather-like, or a pure white soft lump, but it is generally a magnesium silicate lump having fibrous properties. For the time being, although it is classified as a one-dimensional structure clay, it can be considered as a crystalline three-dimensional structure of bricks that can be easily shaved in a certain direction depending on the viewpoint, and a crystal form group consisting of silicon, magnesium, oxygen, hydroxyl group, and crystal water is formed. Is forming. Physical properties have basic properties such as adsorption, thixotropy, and solidification.

Examples of papermaking (sheets) using this characteristic are, for example, JP-A-51-88799, JP-A-56-165097, and JP-A-58-95636.
JP-A-58-144196, JP-A-59
-21800, JP 61-258099, JP 63-235600, and JP 64-6.
There is a technology described in Japanese Patent No. 1599.

[0008]

In the above publication, sepiolite, which is rich in adsorptivity, thixotropy and solidification, is used as an auxiliary for inorganic fibers such as ceramic fibers and cloth, that is, fibers composed of organic fibers or both. In many cases, they are mixed, dispersed, processed, and dried. This is because sepiolite is a fine fiber, so when it is made into a sheet (paper), it has poor drainage, it is difficult to form any sheet, and tear strength is inferior. Because it is difficult to make paper. For this reason, it is naturally difficult to perform the mold forming by making the paper in the slurry using the forming die formed by the paper making. As a result, the excellent properties of sepiolite have not been fully utilized. Japanese Unexamined Patent Publication No. 59-21800 discloses a single use of sepiolite fiber alone, but lacks specific technical contents and lacks practicality.

Further, the sheet is often required to have high strength and water resistance in addition to flameproofness and nonflammability. However, in the above-mentioned publication, there is almost no description of a technique relating to water resistance. In Japanese Patent Laid-Open No. 59-21800, there is described a technique in which a small amount of a resin such as silicone or Teflon is mixed as an inorganic filter paper to improve water resistance, heat resistance and chemical resistance. Is a filter paper, and the specific technical content is not specified, and there is a possibility that it is not practical like the above.

Therefore, an object of the present invention is to provide a nonflammable molded article which has nonflammability and water resistance and can be mass-produced in a slurry for mass production, and a manufacturing method thereof.

[0011]

The non-combustible mold-formed article according to the present invention is obtained by immersing a mold made of paper net in a slurry containing sepiolite as a main material, and vacuum-sucking the above-mentioned paper net. After the paper layer is formed on the mold, it is released and dehydrated and dried.

Further, the method for producing a nonflammable molded article according to the present invention comprises a step of forming a stock containing a slurry containing sepiolite as a main material, and immersing a forming die formed by a paper making machine in the slurry. A mold forming step of forming a paper layer on the paper making machine by vacuum suction, and a drying step of dewatering and drying after releasing the paper layer formed on the paper making machine.

[0013]

The nonflammable molded product of the present invention is inexpensive because it is made by using a mold to make a slurry containing inorganic fiber sepiolite as a main material and drying and solidifying the paper layer on the mold. And has noncombustibility and water resistance.

Further, according to the method for producing a nonflammable molded article of the present invention, a simple process of immersing the molding die formed by the papermaking machine in a slurry containing sepiolite as a main material and vacuum suction is performed. In addition, papermaking can be performed on the papermaking net, and as a result, the nonflammable sheet can be molded at low cost and efficiently.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS.

First, an example of the raw material composition of this embodiment is shown.

[0017]

[Table 1]

In the table, DMAEM is dimethylaminoethyl methacrylate (hereinafter the same), AA is acrylamidoacrylic acid copolymer (hereinafter the same), which are used in this example as the strong cationic polymer and the strong anionic polymer, respectively. Is.

These aggregating agents are liquid high-molecular polymers, and their compounding ratios all represent the polymer pure content, that is, the solid content weight ratio.

In general, there is no strict definition of "strong cationic polymer" and "strong anionic polymer", but in the present invention, "strong cationic polymer" means that the cation is 3.5 meq / g or more. Say something, and also
The “strong anionic polymer” means that the type of anionic polymer flocculant is limited, so the ionicity is judged from general applications, and the ratio of dissociation into anions in water is 20.
% Or more, that is, the ratio of not dissociated is 80% or less.

The compounding ratio of these flocculants will be described later.

In this example, water was added to the raw material having the above mixing ratio to dilute it to 0.2 to 0.5%, and this was used as the papermaking concentration.

Next, the production of a nonflammable molded product having the above composition will be described.

FIG. 1 is an explanatory view showing an outline of a manufacturing process of a nonflammable molded article in one embodiment of the present invention.

In the drawing, in the defibration step A, sepiolite as a main raw material, glass fiber as a reinforcing material, wood pulp as a reinforcing fiber and synthetic fiber are put into a defibrating machine and defibrated by stirring to disperse the fibers. Improve In this example, if the amount of wood pulp is 5% by weight or more, nonflammability will be impaired, so the amount is limited to 5% by weight or less.

Next, in the raw material mixing step B, the disentangled paper material, a binder for fixing, a binder for improving water resistance,
A softener, a stabilizer, etc. are put in a mixing tank and mixed to prepare a slurry. Among them, the binder for fixing is to bond fibers, and for example, it is desirable to add PAA (polyacrylamide) made of a thermoplastic resin in a proportion of about 2% by weight or less, and water resistance. The improving binder imparts water resistance to the molded product, and for example, it is desirable to add EPA (polyamide polyamine epichlorohydrin), which is a thermosetting resin, in a proportion of about 2% by weight or less.

The slurry mixed in the raw material mixing step B is
In order to carry out a coagulation treatment suitable for papermaking, in a process step C, a focusing reaction device is used to perform focusing. As shown in the above table, the coagulant used here is a combination of a strong cationic polymer and a strong anionic polymer.

Next, the slurry prepared in the processing step C is sent to a stock tank, and in a storage step D in which the mixed state is maintained to be always uniform so that sedimentation separation or collapse of the prepared sheet does not occur. enter.

From the above defibration step A to accumulation step D,
It constitutes a stock making process for forming a slurry containing sepiolite as a main material.

Thereafter, the slurry uniformly maintained in the accumulating step D is pumped up to the metering hopper by a metering pump,
Lead to the molding step E.

In the molding step E, a case of molding a semi-cylindrical molded article will be taken as an example and will be described with reference to FIGS. 2 and 3.

FIG. 2 is a schematic view showing a molding apparatus for a nonflammable molded product according to one embodiment of the present invention, and FIG. 3 is a perspective view showing a molded product molded according to one embodiment of the present invention.

In the figure, reference numeral 1 is a slurry which is formed by the above paper making step by adding a coagulant which is mainly composed of sepiolite and which is a combination of a strong cationic polymer and a strong anionic polymer, and 2 is a slurry tank. 3 is a molding apparatus, 4 is a main body of the molding apparatus 3, and a papermaking machine mounting portion 4a formed of steel or the like in a substantially semi-cylindrical shape, and an air hole formed at an upper end of the papermaking machine mounting portion 4a. And a suction pipe 4b that is in close contact with and in communication with the suction pipe 4b.
Reference numeral 5 denotes a paper making mold which is detachably attached to the opening surface portion of the paper making die mounting portion 4a via a holder 6, and 6
A wire mesh of 0 to 80 mesh is formed according to the shape of the molded product in consideration of the plate thickness of the molded product. Reference numeral 7 is a hose, and 8 is a vacuum pump. Reference numeral 9 denotes a semi-cylindrical shaped paper layer adhered to the entire surface of the papermaking mold 5, and 10 denotes a molded product completed by dehydrating and drying the molding paper layer 9.

Molding apparatus 3 constructed as described above
In order to manufacture the molded article 10 by using, the mold forming apparatus 3 is immersed in the slurry 1 and then the vacuum pump 8 is operated to suck the inside of the main body 4 of the mold forming apparatus 3 under vacuum. Then, the water in the surrounding slurry is filtered by the papermaking mold 5 by this suction force and sucked into the main body 4,
The solid content centered on sepiolite in the slurry 1 forms a cake of substantially uniform thickness on the entire surface of the papermaking mold 5 in a state of being dehydrated by a predetermined amount to form the forming paper layer 9. The thickness of the forming paper layer 9 at this time can be controlled by the vacuum pressure by the vacuum pump 8, the suction time, and the like. In this embodiment, the thickness of the molding paper layer 9 is controlled by suctioning the vacuum pressure of 400 to 600 mmHg for 10 to 30 seconds. A thickness of 5 to 2.0 mm was formed. After that, the molding apparatus 3 is taken out of the slurry 1, and air is jetted into the main body 4 from the opposite direction to release the molding paper layer 9 attached to the surface of the papermaking mold 5.

After the molding process as described above, since the molding paper layer 9 contains a considerable amount of water, it is dehydrated and dried.

First, in the preliminary drying step F, the entire molding paper layer 9 is dried by natural drying or warm air drying so as to reduce the water content to 3
0 to 50%.

Then, in the cold press molding step G, the surface is smoothed, bonding with a different material, embossing treatment,
For the purpose of controlling the thickness and the like, the molding paper layer 9 is set on a predetermined mold, and a pressure of 10 to 30 Kg / cm ² is applied so that the moisture content becomes 2
Reduce to 0-30%.

After that, a trimming step H is performed, and end face cutting or the like is performed for shaping.

Then, in the drying step I, the molding paper layer 9 is dried for a predetermined time at an ambient temperature of about 120 ° C. while holding the molding paper layer 9 in a constant shape by using a holding die.
Moisture inside evaporates and condensation accelerates to dry and solidify.

From the above, an extremely thin mold product 10 of 0.2 to 1.0 mm which is not found in ordinary mold products 10
Is completed. This molded product 10 has high heat resistance, and even if a fire is approached, it emits a little smoke and turns black,
A predetermined shape can be maintained.

Next, the aggregation of the chiller 1 in this embodiment will be described.

In general, when the main raw material is wood pulp, synthetic fiber, inorganic fiber or the like having good drainage property, the coagulant having a solid content of 0.01 to 0.1% by weight relative to the raw material is added to produce electricity. The paper is fixed, the flocs are formed, and it is possible to mass-produce paper.

However, when the main raw material is sepiolite, as described above, the drainage is poor and the tear strength is weak, so that it is possible to withstand mechanical impacts such as pump-up, stirring, and turbulent flow in the papermaking process. Therefore, conventionally, mass production has been difficult.

In this example, a strong cationic polymer and a strong anionic polymer were used, and a predetermined mixing ratio was used to form an ion complex with the slurry 1 for forming the sepiolite main material, which was insolubilized. As a result, a network was formed, and as a result, papermaking at the mass production level became possible.

This will be described based on the experimental data of FIG.

FIG. 4 is a characteristic diagram showing the relationship between the amount of coagulant added and the freeness in one embodiment of the present invention, which is an index of productivity when the amount of various coagulants added is changed. This is an examination of freeness. The freeness of this slurry 1 was diluted in a cylindrical container set with an 80 mesh wire mesh.
1000 cc of water was flowed in, and the filtration amount of water in Slurry 1 in 30 seconds was measured to evaluate.

In the figure, the thin solid line indicates the nonionic polymer, the "strong", "medium", and "weak" cations,
This is a representative example of the case where each coagulant such as “strong”, “medium” and “weak” anions is used “alone”, and each of the coagulants is represented by a thin solid line represented by a characteristic diagram. I drew a curve close to.

On the other hand, when a cation and an anion of a high molecular polymer are used in combination, "weak cation + weak anion"
In the combination of, the curve indicated by a broken line similar to that of the "alone" was drawn, and in the combination of "medium cation + middle anion", the freeness was slightly larger than these. But,
It is difficult to industrially produce this "medium cation + medium anion" with freeness. In addition, in these combinations, the addition amount indicates a value obtained by summing up both cations and anions (the same applies below).

On the other hand, in the case of "strong cation + strong anion", the freeness is about 4 times that of "medium cation + medium anion" at the peak, and a value of this level is sufficient. It is at a level where mass production is possible. From the curve in the figure,
If it is about 2% by weight or more, industrial production is considered possible.
However, if it exceeds 1.0% by weight, the viscosity of the slurry 1 becomes very large, and it becomes difficult to make the paper. Therefore, 0.2
It is determined that the amount of addition is about 1.0% by weight for mass production.

As described above, in the nonflammable molded articles of the above-mentioned examples, the main material was sepiolite, and the strong cationic polymer DMAEM and the strong anionic polymer AA were added as the aggregating agent to the total solid content of the raw materials. 0.2 ~
After adding 1.0% by weight to form a slurry 1, a papermaking die 5 which is a molding die formed by a papermaking net is dipped in the slurry 1 and vacuum-sucked to form the papermaking paper on the papermaking die 5. A layer 9 is formed, which is then released and dehydrated and dried.

Therefore, according to the above embodiment, the molded molded product 10 is inexpensive and non-flammable because the main material is composed of the inorganic fiber sepiolite.
It has water resistance and high strength. Further, it can be made extremely thin, has flexibility, has good workability, and is excellent in aesthetic appearance.

Further, the method for producing the non-combustible mold-molded article of the above-mentioned embodiment is a paper comprising a defibration step A for forming the slurry 1 having sepiolite as a main material, a raw material mixing step B, a processing step C, and an accumulation step D. Formed on the paper making step 5; a molding step E, in which the papermaking mold 5 is dipped in the slurry 1 and vacuum-sucked to form a molding paper layer 9 on the papermaking mold 5; After the mold paper layer 9 is released from the mold, it is composed of a preliminary drying step F as a drying step of dehydrating and drying, a cold press molding step G, and a drying step I.

Therefore, according to the above embodiment, the papermaking mold 5 can be easily molded on the papermaking mold 5 by a simple process of immersing the papermaking mold 5 in the slurry 1 containing sepiolite as a main material and vacuum suction.

Furthermore, in the above-mentioned embodiment, since the coagulant is a combination of the strong cationic polymer and the strong anionic polymer in the molding on the papermaking mold 5, the ion of the slurry 1 for forming the sepiolite main material is used. It forms a complex, insolubilizes it, reduces the amount of attached water, reduces hydrophilicity and tightens flocs, so it is a strong and high yielding material that can withstand mechanical shocks such as pump-up, stirring, and turbulent flow. Flock is formed to improve the papermaking property, productivity,
An economically efficient slurry 1 based on sepiolite 1
It is possible to mass-produce papermaking.

By the way, the molded product 1 of the above embodiment
Although 0 is a semi-cylindrical molded product, it is not limited to this when the present invention is carried out, and for example, a relief, an embossed or other uneven product, a molded product such as a plate or a cup, Alternatively, a general synthetic resin molding such as a cylindrical shape or an elbow shape, a metal press molding, or a shape that cannot be released can be molded.

It is also possible to make it thick and use it as a non-combustible board, for example, to form an uneven surface or to use it in a three-dimensional shape.

Further, when obtaining the molded product 10,
Rather than integrally molding, the ends are joined together by utilizing the viscosity of the forming paper layer 9, or the ends are joined together by using an adhesive or the like after molding and drying to make a finished product. You can also

The coagulant of Slurry 1 in the above-mentioned embodiment is DMAEM as the strong cationic polymer and AA as the strong anionic polymer, but the present invention is not limited to this. The strong cationic polymer and strong anionic polymer applicable as the aggregating agent may be appropriately selected.

Further, since sepiolite itself has a cationic property, it may be possible to mass-produce the paper even if the aggregating agent to be added is only the strong anionic polymer, depending on the operating conditions. This case corresponds to the aspects of claims 3 and 6.

Further, the aggregating agent is not limited to those using a strong cationic polymer or a strong anionic polymer, and in short, any coagulant may be used as long as it is suitable for mass-production papermaking. Good.

In addition, the compounding ratio of each component in the above-mentioned embodiment is
Not limited to the values in the above table, physical properties, drainage,
The most suitable one may be selected according to the application.

Furthermore, the molded product 10 of the above embodiment
Glass fiber is mixed as a reinforcing material, but the material is not limited to this, and various reinforcing materials such as rock wool fiber, stainless fiber, and whiskers can be used. However, glass fiber is most suitable in terms of material cost, cohesive effect, and the like. Depending on the intended use, it is not always necessary to mix the reinforcing material. In an embodiment of this type of invention,
The step of mixing the reinforcing material can be omitted, and the work can be simplified. Further, it is possible to give a smooth texture to the molded product 10 in which glass fibers are mixed and which feels hard. Similarly, it is not always necessary to mix the wood pulp and the synthetic fiber as the reinforcing fibers, and they may be properly used in consideration of the paper-making property and the intended use.

[0063]

INDUSTRIAL APPLICABILITY As described above, the non-combustible mold-formed article of the present invention is formed by immersing the forming die formed by the papermaking machine in a slurry containing sepiolite as a main material, and vacuum-sucking the papermaking machine. After the paper layer is formed on the mold, it is released and dehydrated and dried. Therefore, the molded non-combustible molded product is inexpensive and has non-combustibility and water resistance since the main material is composed of inorganic fiber sepiolite.

Further, the method for producing a nonflammable molded article according to the present invention comprises a step of forming a stock containing a slurry of sepiolite as a main material, and immersing a molding die formed by a paper making machine in the slurry. A mold forming step of forming a paper layer on the paper making machine by vacuum suction, and a drying step of dewatering and drying after releasing the paper layer formed on the paper making machine. Therefore, it is possible to easily mold the above-mentioned papermaking machine by a simple step of immersing the mold made of the papermaking machine in a slurry containing sepiolite as a main material and vacuum suction, which is excellent in productivity and economy. Mass production is possible.

[Brief description of drawings]

FIG. 1 is an explanatory view showing an outline of a manufacturing process of a nonflammable molded product according to an embodiment of the present invention.

FIG. 2 is a schematic view showing a molding apparatus for a nonflammable molded product according to an embodiment of the present invention.

FIG. 3 is a perspective view showing a molded product molded according to an embodiment of the present invention.

FIG. 4 is a characteristic diagram showing the relationship between the amount of coagulant added and freeness in one example of the present invention.

[Explanation of symbols]

 1 Slurry 5 Papermaking 9 Molded paper layer A Fibrillation process B Raw material mixing process C Treatment process D Accumulation process E Mold molding process F Pre-drying process G Cold press molding process I Drying process

Claims (6)

[Claims] 1. A paper mold is formed by immersing a molding die formed by paper making in a slurry containing sepiolite as a main material, and vacuum suction is performed to form a paper layer on the paper making, followed by demolding and dehydration drying. A nonflammable molded product characterized by the following. 2. The slurry is essentially composed of sepiolite as a main material and a polymer flocculant in which a strong cationic polymer and a strong anionic polymer are added in a total solid content of 0.2 to 1.0% by weight in a raw material. The nonflammable molded article according to claim 1, which is a component. 3. The slurry has as essential components a sepiolite as a main material and a polymer flocculant to which a strong anionic polymer is added in a total amount of 0.1 to 0.5% by weight in a raw material. The nonflammable molded article according to claim 1. 4. A paper making step of forming a slurry containing sepiolite as a main material, and immersing a forming die formed by a paper making machine in the slurry and vacuum suction to form a paper layer on the paper making machine. A method for producing a nonflammable molded article, comprising: a molding step of forming the paper layer; and a drying step of dewatering and drying the paper layer formed on the papermaking machine. 5. The slurry is essentially composed of sepiolite as a main material and a polymeric flocculant to which a strong cationic polymer and a strong anionic polymer are added in a total amount of 0.2 to 1.0% by weight based on the solid content of the raw materials. 5. The method for producing a nonflammable molded article according to claim 4, wherein the nonflammable molded article is used as a component. 6. The slurry has as essential components a sepiolite as a main material and a polymer flocculant to which a strong anionic polymer is added in a total amount of 0.1 to 0.5% by weight based on the solid content of the raw material. The method for producing a nonflammable molded article according to claim 4, which is characterized in that.