JPH07216191A - Structural material, production of structural material, and interior trim material for vehicle - Google Patents

Abstract

PURPOSE:To obtain a lightweight rigid structural material which can be formed even at a low temp. or room temp. by binding bamboo fibers with a polyhydric phenol-aldehyde condensate, followed by forming and curring. CONSTITUTION:This structural material formed into a predetermined shape comprises bamboo fibers along or a mixture thereof with other fibers and a cured polyhydric phenol-aldehyde condensate binding the fibers. A polyhydric phenol used in the condensate is desirably either resorcinol or an alkylresorcinol, esp. desirably an alkylresorcinol having a higher rate of reaction with an aldehyde than resorcinol. A polyhydric phenol mixture obtd. by dry distillation of oil shale occurring in Estonia is inexpensive and contains a large amt. of a variety of highly reactive alkylresorcinols in addn. to 5-methylresorcinol to be the most pref. starting polyhydric phenol material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a structural material used as an interior material for a vehicle such as an automobile and a building material.

[0002]

2. Description of the Related Art As a structural material of this type, a synthetic resin, glass fiber, wood fiber, recycled fiber or the like is mixed with a phenol resin as a binder, and the mixture is heat-molded into a predetermined shape and the phenol resin is cured. Is provided.

[0003]

However, the curing temperature of the phenol resin as a binder is a high temperature of about 200 ° C., the efficiency of heat energy in the manufacturing process is poor, and the heat resistance of polyvinyl chloride leather or polypropylene nonwoven fabric is low. It is difficult to superimpose an outer covering material or the like having poor properties at the same time and to form the fibers at the same time, and the fibers or the like may be deteriorated due to the high temperature during the forming. Furthermore, the cured product of the phenol resin was too hard and had brittle defects. Further, in the conventional structural material, it is necessary to increase the density in order to obtain rigidity, which increases the weight of the structural material. Especially, when the structural material is used as a vehicle interior material, this is a problem. It becomes an important issue.

[0004]

[Means for Solving the Problems] As a means for solving the above-mentioned conventional problems, the present invention provides a bamboo fiber alone or a mixed fiber of bamboo fiber and other fibers, and a multivalent binder fiber. Consisting of a cured product of a phenol / aldehyde condensate,
The present invention provides a structural material that is molded into a predetermined shape. The polyhydric phenol / aldehyde condensate is a condensate of a polyhydric phenol with an aldehyde and / or an aldehyde donor, or a polyhydric phenol with 1
It is a cocondensation product of a polyhydric phenol and / or amino compound monomer and an aldehyde and / or an aldehyde donor. The above structural material is a bamboo fiber alone or in a mixed fiber of bamboo fiber and other fibers, the polyhydric phenol / aldehyde condensate is present with or without the addition of a curing agent, and heat molded into a predetermined shape. It is produced by a method of curing the condensate. Further, the present invention provides a vehicle interior material comprising the above structural material and a vehicle interior material obtained by laminating the above structural material on a base material such as a synthetic resin foam as a reinforcing material.

The present invention will be described in detail below. [Polyhydric Phenol] In the polyhydric phenol / aldehyde condensate of the present invention, the polyhydric phenol used for condensation with the aldehyde is resorcin, alkylresorcin, pyrogallol, catechol, alkylcatechol,
Hydroquinone, alkylhydroquinone, phloroglucin, bisphenol, is a polyhydric phenol such as dihydroxynaphthalene, or a mixture of two or more,
Of these polyhydric phenols, preferred is resorcin or alkylresorcin, and particularly preferred is alkylresorcin, which has a faster reaction rate with aldehyde than resorcin. Examples of the above alkylresorcin include 5-methylresorcin, 5-ethylresorcin, and 5
-Propylresorcin, 5-n-butylresorcin,
4,5-dimethylresorcin, 2,5-dimethylresorcin, 4,5-diethylresorcin, 2,5-diethylresorcin, 4,5-dipropylresorcin, 2,5-
Dipropylresorcin, 4-methyl-5-ethylresorcin, 2-methyl-5-ethylresorcin, 2-methyl-5-propylresorcin, 2,4,5-trimethylresorcin, 2,4,5-triethylresorcin, etc. is there. The polyhydric phenol mixture obtained by dry distillation of Estonian oil shale is inexpensive, and contains a large amount of various highly reactive alkylresorcins in addition to 5-methylresorcin, and is therefore the most preferable polyhydric phenol raw material for the present invention. .

[Aldehyde and / or Aldehyde Donor] The aldehyde and / or aldehyde donor used in the present invention means an aldehyde and / or a compound which produces and provides an aldehyde when decomposed,
Formalin, formaldehyde, paraformaldehyde, trioxane, acetaldehyde, propionaldehyde, polyoxymethylene, chloral, hexamethylenetetramine, furfural, glyoxal, n-
Examples thereof include butyraldehyde, caproaldehyde, allyl aldehyde, benzaldehyde, crotonaldehyde, acrolein, tetraoxymethylene, phenylacetaldehyde, o-tolualdehyde, saltylaldehyde and the like, or a mixture of two or more thereof.

[Acid catalyst and alkali catalyst] In the present invention, in the condensation of a polyhydric phenol with an aldehyde and / or an aldehyde donor, or with a polyhydric phenol and / or a polyhydric phenol condensate and a monohydric phenol. And / or during the co-condensation of the monohydric phenol-based condensate and / or the amino-based compound monomer and / or the amino-based condensate with the aldehyde and / or the aldehyde donor, if necessary, an acid catalyst or an alkali catalyst is added. . The amount thereof added is a few wt% or less of the total amount of the polyhydric phenol, monohydric phenol and / or amino compound monomer, and usually 6 wt% (hereinafter simply referred to as%) or less. Examples of the acid catalyst include hydrochloric acid, sulfuric acid, orthophosphoric acid, boric acid, oxalic acid, formic acid, acetic acid, butyric acid, benzenesulfonic acid, phenolsulfonic acid, paratoluenesulfonic acid, naphthalene-α-sulfonic acid, naphthalene-β.
-Inorganic or organic acids such as sulfonic acid, or esters of organic acids such as oxalic acid dimethyl ester, maleic anhydride, acid anhydride such as phthalic anhydride, ammonium chloride,
Ammonium sulfate, ammonium nitrate, ammonium oxalate, ammonium acetate, ammonium phosphate, ammonium thiocyanate, ammonium salts such as ammonium imidosulfonate, monochloroacetic acid and its sodium salt, organic halides such as α, α'dichlorohydrin,
There are triethanolamine hydrochloride, hydrochlorides of amines such as aniline hydrochloride, urea adducts such as salicylate urea adduct, stearic acid urea adduct, heptanoic acid urea adduct, N-trimethyltaurine, zinc chloride and ferric chloride. . Examples of the alkaline catalyst include sodium hydroxide, potassium hydroxide, barium hydroxide, hydroxides of alkaline earth metals such as calcium hydroxide, oxides of alkaline earth metals such as lime, sodium carbonate, Weak acid salts of alkali metals such as sodium sulfite, sodium acetate, sodium phosphate, ammonia, trimethylamine, triethylamine, triethanolamine,
Examples of amines include hexamethylenetetramine and pyridin. You may use together 2 or more types of the said acid catalyst or alkali catalyst.

[Polyhydric phenol / aldehyde condensate]
In the present invention, the polyhydric phenol / aldehyde condensate used as the binder of the bamboo fiber alone or the mixed fiber of the bamboo fiber and the other fiber means the polyhydric phenol and the aldehyde and / or the aldehyde donor as described above. A single condensate or a mixture of two or more condensates condensed in the presence of an acid or alkali catalyst or in the absence of a catalyst, or a polyhydric phenol and a monohydric phenol and / or an amino compound monomer and an aldehyde and / or an aldehyde donor. And, in the presence or absence of an acid or alkali catalyst, in the presence of a catalyst, under heating or at room temperature cocondensation product alone or a mixture of two or more, or the above condensate alone or two or more. The above co-condensate is a single substance or a mixture of two or more types. The condensate or cocondensate may be sulfomethylated with a sulfomethylating agent, and the polyhydric phenol may be complexed with a complexing agent during condensation of the condensate or cocondensate. . Further, in the co-condensation of the polyhydric phenol with the monohydric phenol and / or the amino compound monomer, a part or all of the monomer is replaced with the polyhydric phenol and the monohydric phenol and / or the amino compound monomer with the aldehyde and / or the aldehyde donor. An initial condensation product with the body may be used. Examples of the polyhydric phenol / aldehyde condensate of the present invention include polyhydric phenol / aldehyde condensate, monohydric phenol / polyhydric phenol / aldehyde cocondensate, urea / polyhydric phenol / aldehyde cocondensate, urea / Monohydric phenol / polyhydric phenol / aldehyde cocondensation product, melamine / polyhydric phenol / aldehyde cocondensation product, melamine / monohydric phenol / polyhydric phenol / aldehyde cocondensation product, urea / melamine / polyhydric phenol / aldehyde cocondensation product Compounds, urea, melamine, monohydric phenols, polyhydric phenols, aldehyde co-condensates, etc., or their sulfomethylated products or their complexed products. To obtain a cocondensation product of polyhydric phenol with monohydric phenol and / or amino compound monomer with aldehyde and / or aldehyde donor, polyhydric phenol and / or polyhydric phenol / aldehyde condensate and monohydric phenol And / or a monohydric phenol / aldehyde condensate and / or an amino compound monomer and / or an amino compound monomer / aldehyde condensate are preferably co-condensed with an aldehyde and / or an aldehyde donor if necessary. However, the order of addition and the like is arbitrary and is usually 1 to 24 at room temperature to 100 ° C.
Perform condensation for about an hour. In addition, a polyhydric phenol and / or a polyhydric phenol and / or polyhydric acid are added to a monohydric phenol / aldehyde condensate partially or wholly methylolated or an amino compound monomer / aldehyde condensate partially or wholly methylolated or methylated methylolated. The polyphenol / aldehyde condensate may be added and mixed, and if necessary, an aldehyde and / or an aldehyde donor may be added for cocondensation. When the polyhydric phenol / aldehyde-based condensate of the present invention is condensed or co-condensed, polyhydric phenol, monohydric phenol, amino compound monomer, aldehyde and / or aldehyde donor, condensation catalyst, solvent, sulfomethylating agent, In addition to the complexing agent, as the third component,
If desired, toluene, xylene, coumarone, cyclohexanone, cashew oil, tannins, dammers, shellac, rosin or rosin derivatives, petroleum resin, methanol, ethanol, isopropanol, n-butanol,
Isobutanol, ethylene glycol, diethylene glycol, polyethylene glycol, glycerin, furfuryl alcohol, linseed oil, tung oil, castor oil, etc. alone or in combination of two or more as a co-condensation agent or modifier, at the start of the condensation or co-condensation reaction, during the reaction , Or after the reaction ends,
It may be added or modified. Further, the polyhydric phenol / aldehyde condensate of the present invention may be used as a solid powder which is solidified and pulverized by a method such as room temperature or heat evaporation, vacuum evaporation, spray dryer, precipitation drying of resin by salt folding, pH adjustment, etc. Absent.

[Monohydric Phenol] Monohydric phenol co-condensed with the above-mentioned polyhydric phenol means phenol or o-
Cresol, m-cresol, p-cresol, ethylphenol, iso-propylphenol, xylenol, 3,5-xylenol, butylphenol, t-butylphenol, alkylphenols such as nonylphenol, o-fluorophenol, m-fluorophenol, p-fluoro. Phenol, o-chlorophenol,
m-chlorophenol, p-chlorophenol, o-bromophenol, m-bromophenol, p-bromophenol, o-iodophenol, m-iodophenol, p-iodophenol, o-aminophenol, m
-Monophenol substitution products such as -aminophenol, p-aminophenol, o-nitrophenol, m-nitrophenol, p-nitrophenol, 2,4-dinitrophenol, 2,4,6-trinitrophenol and naphthol Such monohydric phenols are used alone or as a mixture of two or more kinds.

[Amino compound monomer] The amino compound monomer which is co-condensed with the above polyphenol is
Means a single or a mixture of two or more amino compounds that form a curable resin through a condensation reaction with an aldehyde such as carbamide and / or aminoazine.
Examples thereof include thiourea, melamine, thiomelamine, dicyandiamide, guanidine, guanamine, acetoguanamine, benzoguanamine, and 2,6-diamino-1,3-diazine.

[Sulfomethyl Agent] The above polyhydric phenol / aldehyde condensate is added with a sulfomethylating agent, if necessary, when the monohydric phenol, polyhydric phenol or amino compound monomer and aldehyde are condensed or co-condensed. However, the condensate or the cocondensate can be partially sulfomethylated to improve the water solubility on the neutral and acidic sides and delay the curing rate. As the sulfomethylating agent, a water-soluble sulfite salt of sulfite, bisulfite or metabisulfite and a quaternary amine or quaternary ammonium such as alkali metal or trimethylamine or benzyltrimethylammonium, or a water-soluble sulfite salt or aldehyde thereof. Examples thereof include hydroxyalkanesulfonic acid such as hydroxymethanesulfonic acid salt and / or alkali metal salt of hydroxyalkanesulfonic acid obtained by the reaction with.

[Complexing Agent] The complexing agent of the polyhydric phenol / aldehyde condensate of the present invention is used for relaxing the reactivity between the polyhydric phenol and the aldehyde,
Examples of such a complexing agent include compounds having a ketone group or an amide group capable of forming a complex with a hydroxyl group of a polyhydric phenol. Examples thereof include acetone and caprolactam. Acetone is particularly preferable. Is.

[Solvent] The polyhydric phenol / aldehyde condensate of the present invention is mainly provided in the form of a solution, and water is usually used as the solvent for the solution.
If necessary, alcohols such as methanol, ethanol, isopropanol, n-butanol, ethylene glycol, diethylene glycol, polyethylene glycol and the like, water-soluble organic solvents such as acetone and ketones such as methyl ethyl ketone, or a mixture of two or more thereof can be used. Acetone and the like act as a solvent and, at the same time, as a complexing agent for alkylresorcin, and bring about a milder curing reaction. However, in the present invention, a powdery polyhydric phenol / aldehyde condensate obtained by removing the solvent from the above-mentioned solution by a method such as vacuum drying and pulverizing the obtained dry solid is also used.

[Third component] In addition to the above components, the polyhydric phenol / aldehyde condensate of the present invention may contain amino compounds such as monohydric phenol, polyhydric phenol, urea, thiourea, melamine and thiomelamine, if desired. Monomers, monohydric phenol resins, urea resins, amino resins such as melamine resins, natural rubber and its derivatives, styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, ethylene-propylene rubber, isoprene rubber, isoprene- Homopolymers of synthetic rubber such as isobutylene rubber, vinyl acetate, vinyl propionate, styrene, acrylic ester, methacrylic ester, acrylonitrile, acrylic acid, methacrylic acid, maleic acid, vinyl chloride, vinylidene chloride, vinylidyne, etc. Or these bi Two or more copolymers of Le monomer,
Polyurethane, polyamide, epoxy resin, butyral resin, polyethylene, polypropylene, vinyl acetate-ethylene copolymer, chlorinated polyethylene, chlorinated polypropylene, emulsion or latex of various synthetic resins such as polyester, polyvinyl alcohol, sodium alginate, Starch, starch derivatives, glue, gelatin, blood meal, methyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, polyacrylic acid, polyacrylamide and other water-soluble polymers and natural gums, as well as calcium carbonate, talc, gypsum, carbon black, Fillers such as wood flour, walnut flour, coconut husk flour, wheat flour and rice flour, surfactants, higher fatty acids such as stearic acid and palmitic acid, higher alcohols such as palmityl alcohol and stearyl alcohol Esters of fatty acids such as ruthel, butyl stearate, glycerin monostearate, fatty acid amides, natural waxes such as carnauba wax, synthetic waxes, paraffins, paraffin oil, silicone oil, silicone resin, fluororesin, polyvinyl Releasing agents such as alcohol and grease, pigments, dyes, flame retardants, flame retardants, insect repellents, preservatives, anti-aging agents, UV absorbers and DB
A third component such as a phthalate ester plasticizer such as P, DOP or dicyclohexyl phthalate, or another plasticizer such as tricresyl phosphate is added to the polyhydric phenol / aldehyde condensate to co-condensate or mix. The condensate may be modified by, for example,

[Fibers] Fibers used in the structural material of the present invention include bamboo fibers alone, or bamboo fibers and polyester fibers, aliphatic or aromatic polyamide fibers, acrylic fibers, polyethylene fibers, polyolefin fibers such as polypropylene fibers, Vinylidene fiber, polyvinyl chloride fiber,
Polyurethane fibers, chemical fibers such as vinylon, rayon, cupra and acetate, wood fibers such as pulp and wood chips, natural fibers such as cotton, palm fibers, wool and silk, or organic fibers such as recycled fibers of the above chemical fibers and natural fibers. , Mixed fibers in which fibers such as glass fibers, rock wool, ceramic fibers, carbon fibers, and other inorganic fibers are mixed. The above examples do not limit the present invention. Bamboo fiber can be degreased with an aqueous solution of caustic soda, a surfactant, a solvent or the like in advance, or subjected to a pretreatment such as an ultraviolet treatment.

[Manufacturing of Structural Material] The structural material of the present invention is manufactured mainly by the following method. (1) Bamboo fiber alone or a mixed fiber of bamboo fiber and other fibers is mixed with a polyhydric phenol / aldehyde condensate as a binder and, as it is, or 120 ° C or less, preferably 6
A method of drying at a temperature of 0 to 100 ° C. and then heat-molding into a predetermined shape. In this method, the polyphenol
A solution of an aldehyde-based condensate is sprayed onto the fibers to mix them. (2) In the method of (1), preforming is performed before heat forming into a predetermined shape, and the preform is heat formed into a predetermined shape. The preform is usually fleece, felt, non-woven fabric,
It is provided in a sheet state such as a fiber knitted fabric. The sheet-shaped preform is generally produced by a fleece making machine, an entanglement machine, a needle punching machine, a paper making machine, a forming machine, a roll press, etc., but if desired, the above drying temperature is used when producing the preform. The preformed product may be used as a prepreg by heating to the above temperature to make the polyhydric phenol / aldehyde condensate that is the binder into a semi-cured state. (3) Bamboo fiber alone or a mixed fiber of bamboo fiber and other fibers is molded into a predetermined shape and then impregnated with a solution of a polyhydric phenol / aldehyde condensate as a binder by dipping, spraying, etc. Alternatively, it is dried at a temperature of 120 ° C. or lower and then heat-cured. (4) Bamboo fiber alone or mixed fiber of bamboo fiber and other fibers
By the method of (2), for example, a sheet-shaped preform,
The preform is impregnated with a solution of a polyhydric phenol / aldehyde condensate by dipping, spraying or the like, and then heat-molded. The amount of the polyhydric phenol / aldehyde condensate mixed or impregnated into the above-mentioned bamboo fiber alone or a mixed fiber of bamboo fiber and other fiber, or a molded product thereof or a preformed product thereof is usually 100 parts by weight of the fiber (hereinafter simply referred to as "part"). It is a solid content of 1 to 500 parts, preferably 3 to 100 parts, more preferably 5 to 50 parts, usually 5 to 25 parts, and the polyhydric phenol-aldehyde condensate is It is cured by heat molding to bind the fibers. In the production of the structural material, the bamboo fiber alone or the mixed fiber of the bamboo fiber and other fibers may be impregnated with the polyhydric phenol / aldehyde-based condensate or prior to the impregnation of the polyhydric phenol / aldehyde-based condensate. After impregnation, phenolic resin, amino resin,
Thermosetting resin such as epoxy resin, urethane resin, xylene resin, ketone resin, polyester resin, alkyd resin, silicon resin, furan resin, polyethylene, polypropylene, polyolefin, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer Polymers, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, polyethylene terephthalate, thermoplastic acrylic resins, thermoplastic polyesters, thermoplastic polyamides, thermoplastic resins such as nylon, and the like, or a mixture of two or more thereof. It may be mixed or impregnated in the form of powder or solution, and then impregnated with the polyhydric phenol / aldehyde condensate.

[Curing of Polyhydric Phenol / Aldehyde Condensate] Curing of the polyhydric phenol / aldehyde condensate of the present invention is carried out with sufficient methylol groups or methylated methylol groups necessary for curing in the molecule of the condensate. If the quantity is included,
It can be cured by heating without adding a curing agent. However, usually, in the case of the above-mentioned aldehyde and / or aldehyde donor, about 0 to 100 parts of the alkylolated triazone derivative is used per 100 parts of the condensate using an aldehyde and / or an aldehyde donor or an alkylolated triazone derivative as a curing agent. In this case, about 0 to 500 parts are added and mixed, and the mixture is cured at room temperature or by heating. When hexamethylenetetramine and / or an alkylolated triazone derivative is added as the above-mentioned curing agent, it usually does not cure for a long period of time at 90 ° C or lower, but it rapidly cures when heated to 130 to 140 ° C or higher. Therefore, when obtaining the structural material of the present invention, when the bamboo fiber alone or the mixed fiber of the bamboo fiber and other fibers is impregnated with the resin by mixing or dipping, spraying or the like and then immediately molding, the resin is kept at room temperature. Since a high curing speed of the above may be practically acceptable, an ordinary curing agent such as paraformaldehyde or formalin is used. However, when a long storage period after mixing is required, the above hexamethylenetetramine and / or alkyl It is desirable to use rolled triazone derivatives. Further, an acid catalyst or an alkali catalyst as used in the production of the polyhydric phenol / aldehyde condensate may be added and used together with a curing agent. The amount of the above acid catalyst or alkali catalyst added is usually 0.05 to 100 parts by weight of the resin.
It is about 50 copies.

[Alkylolated Triazone Derivative] The alkylolated triazone derivative used as the above-mentioned curing agent is a urea compound, an amine, an aldehyde and / or
Alternatively, it is obtained by reaction with an aldehyde donor. Urea compounds used in the production of alkylolated triazone derivatives include urea, thiourea, alkylurea such as methylurea, alkylthiourea such as methylthiourea, phenylurea, naphthylurea, halogenated phenylurea, nitrated alkylurea. And the like, or a mixture of two or more thereof is exemplified, and a particularly desirable urea compound is urea or thiourea. Also, as amines, aliphatic amines such as methylamine, ethylamine, propylamine, isopropylamine, butylamine, and amylamine, amines such as benzylamine, furfurylamine, ethanolamine, ethylenediamine, hexamethylenediamine, hexamethylenetetramine, and ammonia. Are exemplified, and these are used alone or as a mixture of two or more kinds. The aldehyde and / or aldehyde donor used in the production of the above alkylolated triazone derivative are the same as those used in the polyhydric phenol / aldehyde condensate of the present invention. For the synthesis of the alkylolated triazone derivative of the present invention, usually, amines and / or ammonia 0.1 to 1.2 mol, aldehyde and / or aldehyde donor 1.5 per mol of the urea compound is used.
The reaction is carried out at a ratio of ˜4.0 mol. The order of addition during the reaction is arbitrary, but the preferred reaction method is that the required amount of the aldehyde donor is first added to the reactor, and the required amount of the amines and / or ammonia is usually maintained at a temperature of 60 ° C. or lower. It is to add gradually the required amount of urea compound, and to stir and heat at 80 to 90 ° C. for 2 to 3 hours to react. As the aldehyde and / or the aldehyde donor, 37% formalin is usually used, but part of it may be replaced with paraformaldehyde in order to increase the concentration of the reaction product. The use of hexamethylenetetramine as the aldehyde donor also gives higher solids reaction products. The reaction of the urea compound, the amines and / or ammonia with the aldehyde and / or the aldehyde donor is usually carried out in an aqueous solution, but some or all of the water is methanol, ethanol, isopropanol, n-butanol, ethylene. Alcohols such as glycol and diethylene glycol may be used singly or as a mixture of two or more kinds, and water-soluble organic solvents such as ketones such as acetone and methyl ethyl ketone may be used alone or as a mixture of two or more kinds.

[Laminated Material] The structural material or preformed body manufactured as described above may be formed by laminating two or more layers of the same kind or different kinds, or reinforced on both sides or one side of the structural material or preformed body. You may laminate a material, a cover material, a base material, etc.
As the reinforcing material, the covering material, the substrate, etc., the organic or inorganic fiber knitted woven fabric or non-woven fabric, a gauze cloth, a mesh body such as a wire mesh,
There are metal materials such as metal frames and metal plates, used paper, cardboard, resin felt, plastic sheets, carpets, synthetic leather, plastic foam sheets and the like. Examples of the synthetic leather include polyvinyl chloride leather, polyamide leather, and amino acid leather, and examples of the plastic foam sheet include a polyethylene foam sheet, a polypropylene foam sheet, a polyurethane foam sheet, and a melamine resin foam sheet. The non-woven fabric or synthetic leather may be lined with the plastic foam sheet as a cushioning material. Further, the reinforcing material and the facing material may be laminated together on the structural material or the preformed body. (3) above
Alternatively, in the case of the method of (4), that is, when the above-mentioned structural material or preform is impregnated with the polyhydric phenol / aldehyde condensate by dipping, spraying or the like, the reinforcing material, the covering material, etc. are not laminated. It is performed before or after coating and impregnating the condensate. Further, when the reinforcing material, the covering material and the like are porous bodies, the condensate may be coated and impregnated on the reinforcing material, the covering material and the like. When the structural material or preform has a relatively weak strength against pulling such as a cotton-like body or an entangled body, the structural material or preform is preliminarily loaded with the reinforcing material or the covering material. When the condensate is impregnated after pasting with an adhesive or the like, there is no deviation or peeling between the structural material or the preform and the reinforcing material, the covering material, etc. during the impregnation work, and the condensate is a solution. In this case, the solution does not cause deviation or peeling due to swelling of the structural material or the preform, and continuous operation is possible, and deviation or peeling does not occur even during drying, which is particularly preferable. Further, when laminating the reinforcing material, the covering material or the like on the structural material or the preform, when the reinforcing material, the covering material or the like is composed of a directional fiber substance, the structural material or the preform and the fiber It is, of course, possible to change the directionality of the layers in the same manner even when the directionality is changed, or in the case where two or more layers of the directional structural material or preforms are laminated. In this case, the strength of the structural material is further improved. An adhesive, a hot-melt adhesive, a hot-melt sheet, an ordinary adhesive or the like is used for laminating the reinforcing material, the covering material or the like on the structural material or the preform, and the reinforcing material, the covering material or the like is used. An adhesive is not necessarily required when impregnating the polyhydric phenol / aldehyde condensate or other synthetic resin.

[Heat Forming] As described above, the structural material of the present invention is prepared by mixing bamboo fiber alone or a mixed fiber of bamboo fiber and other fibers with a polyhydric phenol / aldehyde type condensate, or preforming the mixture. After molding, or after laminating two or more layers with each other, or immediately after laminating reinforcing materials, covering materials, etc., or after storing for a required period, cut into a predetermined shape, or perform molding by hot pressing without cutting. . When forming by laminating a reinforcing material, a covering material, etc., if the reinforcing material, the covering material, etc. have no air permeability such as a metal plate or a plastic sheet, vacuum forming is possible other than hot pressing. . Also, as described above, the reinforcing material,
The covering material and the like may be laminated after molding. Since the polyhydric phenol / aldehyde-based condensate of the present invention can be cured at a low temperature of 200 ° C. or lower, preferably 140 ° C. or lower, the heat molding temperature is accordingly reduced to 200 ° C. or lower, and if desired, 140 ° C. or lower. Even if the surface material is poor in heat resistance, such as polypropylene nonwoven fabric or polyvinyl chloride leather, it can be molded before or simultaneously with the molding of the structural material or the preform.

[Use] As described above, since the structural material of the present invention is lightweight and has rigidity, it is a structural building material such as an outer wall material, an inner wall material, and a soundproof material, a ceiling material for a vehicle such as an automobile, a door trim, and a dash. Used for interior materials such as boards, tonneau boards, and lining materials for luggage compartments. In the interior materials for vehicles such as automobiles, the structural material of the present invention is used as a base material or as a reinforcing material for a base material instead of glass fiber. As the base material on which the structural material of the present invention is laminated as a reinforcing material, a polyurethane foam, a polystyrene foam,
There are plastic foams such as polyethylene foams, polypropylene foams, phenol resin foams, melamine resin foams, amino resin foams such as urea resin foams, cardboard, resin felt, waste paper boards and the like. The above-mentioned substrate is polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, fluororesin, thermoplastic acrylic resin, thermoplastic polyester, Thermoplastic polyamide, thermoplastic urethane resin, acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, acrylonitrile-butadiene-styrene copolymer, ethylene-propylene copolymer, ethylene-propylene terpolymer, ethylene-vinyl acetate copolymer Thermoplastic synthetic resins such as polymers, natural rubber,
Natural or synthetic rubber such as chloroprene rubber, nitrile rubber, butyl rubber, urethane resin, melamine resin, thermosetting acrylic resin, urea resin, benzoguanamine resin, ketone resin, phenol resin, polyphenol resin, epoxy resin, thermosetting Thermosetting synthetic resin such as type polyester, allyl resin, silicone resin, alkyd resin,
Polycarbonate resin, acetal resin, coumarone indene resin, petroleum resin, or urethane resin prepolymer, epoxy resin prepolymer, melamine resin prepolymer, urea resin prepolymer, phenol resin prepolymer, diallyl phthalate prepolymer that produces the above synthetic resin. , Acrylic oligomer, polyvalent isocyanate, methacrylic ester monomer, prepolymer such as diallyl phthalate monomer, oligomer, monomer and polyvinyl alcohol, sodium alginate, starch, starch derivative, glue, gelatin, blood powder, methyl cellulose,
Carboxymethyl cellulose, hydroxyethyl cellulose, polyacrylic acid, may be applied or impregnated with water-soluble polymers such as polyacrylamide, natural gums, further calcium carbonate, talc, gypsum, carbon black,
Fillers such as wood flour, walnut flour, coconut husk flour, wheat flour and rice flour, surfactants, higher fatty acids such as stearic acid and palmitic acid, higher alcohols such as palmityl alcohol and stearyl alcohol, butyl stearate, glycerin monostearate Fatty acid esters such as, fatty acid amides, natural waxes such as carnauba wax, synthetic waxes, paraffins, paraffin oil, silicone oil, silicone resin, fluororesin, polyvinyl alcohol, release agents such as grease, pigments , Flame retardants such as dyes, flame retardants, antimony trioxide, aluminum hydroxide and bromine compounds, insect repellents, preservatives, anti-aging agents, UV absorbers, water repellents, chemical foaming agents, capsule foaming agents and DBPs. , DOP,
One or more co-condensates or mixtures of phthalic acid ester plasticizers such as dicyclohexyl phthalate and other plasticizers such as tricresyl phosphate may be applied, impregnated or mixed. Further, the structural material of the present invention does not cause the work environment to deteriorate due to scattering of small pieces unlike glass fiber, and is lighter than glass fiber, and thus is extremely useful as a reinforcing material.

[0022]

In the structural material of the present invention, the polyhydric phenol / aldehyde condensate or the sulfomethylated product of the condensate is stable in a wide pH range, has room temperature curability, and has a long pot life and a short reaction time. To cure. Therefore, the structural material of the present invention can be efficiently formed by heating at a low temperature, and the cured product thereof is extremely excellent in flexibility, water resistance, heat resistance, weather resistance and the like. Further, the bamboo fiber constituting the structural material is rich in rigidity, and a structural material having rigidity can be obtained even if the density is roughened to reduce the weight.

[0023]

【Example】

[Example 1] 1 mol of resorcin and 37% formalin 0.
0.1 mol of caustic soda was added to 5 mol and reacted 50
% Polyphenol / aldehyde condensate 100 parts and a liquid binder mixture containing 20 parts of hexamethylenetetramine as a curing agent are spray-mixed to the bamboo fiber so as to have a solid content of 12%, and at 60 ° C. or lower. dry. Bamboo fiber mixed with the liquid binder mixture is pressed at room temperature using a fleece manufacturing machine to form a mat-shaped preform, and the preform is 170 ° C. and a pressure of 2.5 kg / cm ² for 40 seconds. It was hot pressed to form a plate having a specific gravity of 0.3 and a thickness of 5 mm. In this way, a plate-like structural material that is lightweight, highly rigid and excellent in heat resistance was obtained.

Example 2 1 mol of phenol, 0.4 mol of 5-methylresorcinol, 2.1 mol of 37% formalin at a ratio of 0.1 mol of caustic soda and 50% monohydric phenol / polyhydric phenol / aldehyde Cocondensate 100
Part, 45% paraffin emulsion as a release agent.
A liquid binder mixture containing 5 parts and 1 part of 40% ammonium phosphate as a flame retardant was mixed with 80% bamboo fiber and 20 hemp fiber.
% Of a mixed fiber of 10% as a solid content, spray-dried and dried at 100 ° C. or lower, and then pressed at room temperature using a fleece maker to form a mat-shaped preform. And the preform at 170 ° C., 2 kg / cm
Hot pressed at a pressure of ² for 50 seconds, specific gravity 0.7 thickness 3
It was formed into a mm plate. In this way, a plate-like structural material that is lightweight, highly rigid and excellent in heat resistance was obtained.

Example 3 Alkylresorcin (boiling point 270 to 290 ° C.) 1 obtained by purifying shale oil resorcin obtained by dry distillation of Estonian oil shale 1
Mol, urea 0.8 mol, 37% formalin 0.5 mol and caustic soda 0.1 mol added and condensed to 60% polyhydric phenol / urea / aldehyde cocondensate 100 parts hexamethylenetetramine 15 parts as a curing agent 90% bamboo fiber and 10 polyester fibers were added to the liquid binder mixture.
% To a mixed fiber of 8% as a solid content, and then entangled with a needle punch to form a mat-shaped fiber entangled body.
Hot pressing was performed for 40 seconds at a pressure of 3 kg / cm ^{2 to} obtain a specific gravity of 0.
9. Formed into a plate having a thickness of 2.5 mm. In this way, a plate-like structural material that is lightweight, highly rigid and excellent in heat resistance was obtained.

[Example 4] 1,5-dimethylresorcinol 1 mol, phenol 0.7 mol, melamine 0.3 mol,
To 100 parts of sulfomethylated 60% polyphenol / monophenol / melamine / aldehyde cocondensate reacted with 37% formalin (1 mol) and sodium sulfite (0.4 mol), urea, methylamine and A liquid binder mixture obtained by adding 100 parts of 50% alkylolated triazone derivative obtained by the reaction of 37% formalin is added in an amount of 10% in terms of solid content with respect to a mixed fiber consisting of 80% bamboo fiber and 20% polypropylene fiber. Spray-mix as described above, then dry at 60 ° C., and then press at room temperature using a fleece maker to obtain a mat-shaped preform, and press the preform at 130 ° C. for 30 seconds to give a mat. -Shaped prepreg, stored at room temperature for 7 days, 30 days, 60 days, and then stored at 180 ° C for 3 kg /
It was hot pressed at a pressure of cm ² for 1 minute to form a plate having a thickness of 2.5 mm and a specific gravity of 0.8. In this way lightweight and rigid,
A plate-like structural material having excellent heat resistance and bending strength was obtained. In the plate-shaped structural material of this example, the polypropylene fibers contained during the hot pressing are softened and the bamboo fibers are entangled with each other to improve the rigidity.

[Example 5] 1 mol of 5-ethylresorcin, 0.2 mol of m-cresol, 0.8 mol of urea, 0.2 mol of sodium sulfite, 2.1 mol of 37% formalin and adjusted to pH 5.1. The sulfomethylated polyhydric phenol / monohydric phenol / urea / aldehyde cocondensate was dried by vacuum evaporation at 60 ° C. or lower and pulverized to about 100 mesh. A powdery binder mixture prepared by adding 20 parts of paraformaldehyde as a curing agent to 100 parts of the powder of the polyhydric phenol / aldehyde condensate produced in this manner was prepared from bamboo fiber 70%, recycled fiber 10% and pulp 20%. It is added to the mixed fiber so as to be 12% and entangled in a sheet shape by an entanglement machine, and the fiber entangled body is hot-pressed at 100 ° C. and a pressure of 2.5 kg / cm ² for 30 seconds to obtain a thickness. It was formed into a sheet having a size of 1 mm and a specific gravity of 0.6.
In this way, a lightweight sheet-like structural material having excellent heat resistance, rigidity and strength was obtained.

Example 6 Bamboo fiber 90%, coconut fiber 10
%, The liquid binder mixture of Example 1 is spray-mixed to the mixed fibers so that the added amount of solid content is 15%, and the mixture is dried at 60 ° C. or lower.
The mixed fiber mixed with the liquid binder mixture is sprinkled on a mold to form a mat, and the mat is heated to 170 ° C.
Hot press for 40 seconds, thickness 0.5mm, specific gravity 0.2
When formed into a sheet, a sheet-like structural material having good weight and high rigidity was obtained.

Comparative Example 1 50% consisting of 1 mol of phenol, 2 mol of 37% formalin and 0.2 mol of caustic soda
Using a resol-type phenol / aldehyde condensate as a binder, spray coating was applied to bamboo fiber so that the coating amount was 12% in terms of solid content, followed by drying at 60 ° C. and then hot pressing. At this time, when the hot pressing temperature was 180 ° C., the required hardening was 1 minute or more, and when the hot pressing temperature was 170 ° C., the hardening was insufficient and the rigidity and strength were insufficient even after hot pressing for 3 minutes.

[Embodiment 7] In the hot press of Embodiment 1, the plate-shaped structural material is formed into a base material shape of an automobile door trim. As shown in FIG. 1, the base material (1) is a vacuum pressure bonding machine (4).
Set on the lower mold (5) and covered with polyvinyl chloride leather and polypropylene foam sheet.
Set the back surface of (2) with polyester hot melt adhesive (3) applied, press the surface mounting material (2) on the surface of the base material (1) and press it with the upper mold (6). .
In this way, the automobile door trim (7) as shown in FIG. 2, which is lightweight, highly rigid and excellent in heat resistance, is manufactured.

Example 8 The fiber entangled body of Example 3 was set as a base material (11) on the lower mold (15) of the automobile molding ceiling press molding machine (14) shown in FIG. A surface material (12) made of polypropylene needle non-woven fabric lined with a polyethylene hot melt sheet (13) is set, and 150 ° C. between the lower mold (15) and the upper mold (16) of the press molding machine (14), 3 kg /
Hot press for 30 seconds at a pressure of cm ² . After that, trimming is performed to form a molded ceiling material for automobiles as shown in FIG.
Get (17). The molded ceiling material (17) is lightweight and highly rigid, and has excellent heat resistance and shape retention.

[Embodiment 9] The sheet-like structural material of Embodiment 5 is set as a reinforcing material (21) on the lower mold (25) of the automobile forming ceiling vacuum forming machine (24) shown in FIG. The base material (23), which is a polystyrene foam plate heat-softened at 150 ° C., and a polypropylene fiber non-woven fabric, and an exterior material (22) lined with an ethylene-vinyl acetate copolymer are overlaid, vacuum-molded, and a lower mold ( The stack is clamped between 25) and the upper mold (26). In this way, a molded ceiling material for an automobile having the same shape as that shown in FIG. 4 of Example 7 is obtained. Since the molded ceiling material is reinforced by the reinforcing material (21), it is lightweight, highly rigid, and excellent in heat resistance and shape retention.

[Embodiment 10] As shown in FIG. 6, a polyvinyl chloride sheet (31) is molded into the shape of an automobile dashboard, and the polyvinyl chloride sheet (31) is preformed with a preform of Example 2 using an acrylic resin. 150 by pressing with an adhesive
The polyhydric phenol / aldehyde condensate in the preformed product is polymerized and cured by heating at 1 ° C. for 1 minute to obtain an insulator (32). In this way, the automobile dashboard (33) is manufactured.

[Embodiment 11] In the hot press of Embodiment 3, the plate-like structural material is molded so as to conform to the shape of the floor of the automobile to produce a carpet underlay (42) having the shape shown in FIG. 7. The underlay (42) is set on the lower die (45) of the carpet molding machine (44), and the carpet (41) in which the lined polyethylene sheet (43) is heated and softened is placed on the underlay (42). The carpet (41) is molded by sandwiching the mold (45) and the upper mold (46), and at the same time, the underlay (42) is pressure-bonded through the polyethylene sheet (43). In this way, the molded carpet (47) for automobile floor covering as shown in FIG. 8 is manufactured.

[Embodiment 12] On the lower die (57) of the automobile molding ceiling press molding machine (56) shown in FIG. 9, diphenylmethane-4.
The polyurethane foam sheet (52) impregnated with 4% -diisocyanate (MDI) was laminated on both sides with the sheet-like structural material of Example 6 as the reinforcing material (51, 51), and the polyamide hot melt nonwoven fabric was further laminated thereon. (55) lined polypropylene needle punched non-woven surface material (54) is set, the press molding machine (56) between the lower mold (57) and the upper mold (58) 150 ℃, 3kg / cm Hot press at a pressure of ² for 1 minute. Sheet-shaped reinforcing material (51,
51) is a polyurethane foam sheet (52) impregnated with M
It is adhered by the exudation of DI, and the covering material (54) is adhered by softening the polyamide hot melt nonwoven fabric (55). After that, trimming is performed to obtain a molded ceiling material for automobiles having a shape similar to that shown in FIG. Since the molded ceiling material is reinforced by the reinforcing material (51, 51), it is lightweight and highly rigid, and has excellent heat resistance and shape retention.

[Embodiment 13] A heat insulating material (62) made of the structural material of Embodiment 1 between the concrete formwork (67, 67) shown in FIG.
Then, concrete is placed after inserting the reinforcing rods (66) and the reinforcing bars (66) to form a concrete skeleton wall (63) having a heat insulating material (62) attached to the inner surface as shown in FIG. After releasing the formwork (67, 67), the mortar cement layer (6
4) is applied, and a decorative sheet (65) is attached to the inner surface of the mortar cement layer (64) to construct a building wall (61).
Since the heat insulating material (62) is porous, the concrete frame (63)
And the adhesion of the mortar cement layer (64) to the heat insulating material (62) is extremely excellent.

In addition to the above-mentioned embodiments, the structural material of the present invention is used for various automobile interior materials such as seat cushion, seat back pad material, visor pad material, trunk room lining material, trunk room lid lining material, etc. However, it is also used as a heat insulating material for floors of buildings.

[0038]

Therefore, according to the present invention, there is provided a structural material which is light in weight, rich in rigidity, and moldable at low temperature or room temperature.

[Brief description of drawings]

 1 and 2 relate to the seventh embodiment.

FIG. 1 is a sectional view of a vacuum pressure bonding process.

FIG. 2 is a perspective view of a door trim. FIGS. 3 and 4 relate to an eighth embodiment.

FIG. 3 is a sectional view of a molding process.

FIG. 4 is a perspective view of an automobile molded ceiling.

FIG. 5 is a sectional view of a molding process in Example 9.

FIG. 6 is a perspective view of a dashboard according to a tenth embodiment. FIGS. 7 and 8 relate to the eleventh embodiment.

FIG. 7 is a sectional view of a carpet molding process.

FIG. 8 is a sectional view of a molded carpet.

FIG. 9 is a cross-sectional view of the molding step in Example 12 FIGS. 10 and 11 relate to Example 13.

FIG. 10: Cross-sectional view of concrete formwork

FIG. 11 is a sectional view of the wall.

[Explanation of symbols]

 1,11,23,52 Base material 7 Door trim 17 Molded ceiling material 33 Dashboard 42 Carpet underlay 21,51 Reinforcement material 62 Insulation material

Claims (12)

[Claims] 1. A bamboo fiber alone or a mixed fiber of bamboo fiber and another fiber, and a cured product of a polyhydric phenol / aldehyde condensate that binds the fiber and is molded into a predetermined shape. Structural material characterized by 2. The structural material according to claim 1, wherein the polyhydric phenol / aldehyde condensate is a condensate of a polyhydric phenol with an aldehyde and / or an aldehyde donor. 3. The polyhydric phenol / aldehyde-based condensate is a co-condensate of a polyhydric phenol, a monohydric phenol and / or an amino compound monomer, and an aldehyde and / or an aldehyde donor. Structural material described in 4. The structural material according to claim 1, wherein a part or all of the polyhydric phenol is alkylresorcin. 5. The structural material according to claim 1, wherein the cocondensate is sulfomethylated. 6. A polyhydric phenol / aldehyde condensate is present in a bamboo fiber alone or in a mixed fiber of a bamboo fiber and another fiber, with or without a curing agent, and heat-molded into a predetermined shape. And a method for producing a structural material, characterized in that the condensate is cured. 7. A bamboo fiber alone or a mixture of bamboo fiber and other fibers in which the polyhydric phenol / aldehyde condensate is present is preformed into a sheet and then heat-formed into a predetermined shape. Item 6. A method for manufacturing a structural material according to item 6. 8. The polyphenol / aldehyde-based condensate is provided as a solution, and the solution is mixed with the bamboo fiber alone or a mixed fiber of bamboo fiber and other fibers. Structural material manufacturing method 9. The method for producing a structural material according to claim 6, 7 or 8, wherein the curing agent is hexamethylenetetramine and / or an alkylolated triazone derivative. 10. A vehicle interior material comprising the structural material according to claim 1. 11. An interior material for a vehicle, characterized in that the structural material according to claim 1 is laminated on a base material as a reinforcing material. 12. The base material is a synthetic resin foam.
1. Interior material for vehicle according to 1.