JPH07223209A - Fibrous molding and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain a molding with the same degree of density as a polystyrene foam using a fibrous material. CONSTITUTION:A space between the inner force 2 and the outer force 3 of a molding die l is filled with a molding material 4 consisting of a mixture of a fiber and a binder to such a range of final density of 12g/l to 50g/l. In addition, a medium of such a nature as to cure or dry a binder in a molding material is sprayed through the porous die face 2A of the inner force 2 and/or the outer force 3, so that the binder becomes cured or dried.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber molding used for insulation boards, packaging materials and the like, and a method for producing the same.

[0002]

BACKGROUND OF THE INVENTION Polystyrene foam is conventionally used for insulation boards, packaging materials and the like. However, the above polystyrene foam has a problem in scrap processing. For example, even if the polystyrene foam is melted and reused as pellets for molding, the demand amount of the polystyrene molded product is extremely small compared to the scrap amount of the polystyrene foam. Therefore, most of the polystyrene foam scrap is incinerated, but the polystyrene foam scrap contains a large amount of carbon, and when incinerated, produces a large amount of black smoke and pollutes the environment.

[0003]

2. Description of the Related Art Recently, as a material to replace the above polystyrene foam, a molded article obtained by binding fibers of waste paper pulp with a binder has been provided. The waste paper pulp does not generate black smoke even when incinerated, and can be biodegraded, and the biodegraded product is used as compost. Conventionally, molded articles of fibers such as the above waste paper pulp are produced by a papermaking method from a fiber slurry, a dry method or a semi-dry method of press-molding a mixture of fibers and a binder, and the like.

[0004]

However, the above-mentioned papermaking method is troublesome in production, particularly in the drying step, and it is not possible to obtain a low-density one which is equivalent to polystyrene foam, and the above-mentioned dry method or semi-dry method is used. Also, in order to cure or dry the binder, the compressibility at the time of hot pressing must be increased, and even with these methods, a low density such as polystyrene foam cannot be obtained.

[0005]

Means for Solving the Problems As a means for solving the above-mentioned conventional problems, the present invention provides a porous molded article (5) obtained by binding fibers with a binder to form a desired shape. Fiber moldings in the range of 12 g / l to 50 g / l
(5), which is composed of an inner mold (2) and an outer mold (3), and a mold surface (2A, 3A) of the outer mold (2) and / or the inner mold (3).
Using a mold (1) having a porous structure, a molding material (4) consisting of a mixture of fibers and a binder is placed between the inner mold (2) and the outer mold (3) of the mold (1). It is packed so that the final density is 12 g / l to 50 g / l, and the binder is cured and / or cured from the porous mold surface (2A, 3A) of the inner mold (2) and / or the outer mold (3). Alternatively, the molding material (4) is sprayed onto the molding material (4) by drying it.
The present invention provides a method for producing a fiber molded product (5), which comprises curing and / or drying the above binder.

The fibers used in the present invention include:
For example, pulp, wood wool, wood chips, wood fibers such as waste paper pulp obtained by loosening waste paper, polyester fibers, polypropylene fibers, polyamide fibers, acrylic fibers, acetate fibers, organic fibers such as cotton, glass fibers, ceramic fibers,
There are inorganic fibers such as carbon fibers, or recycled fibers obtained by defibrating scraps such as carpets, felts, and nonwoven fabrics made of the above organic or inorganic fibers, and the above fibers may be mixed in two or more kinds. Among the above fibers, preferred one is waste paper pulp obtained by defibrating waste paper.

For the above fibers, if desired, polystyrene,
Chips of plastics such as polyethylene, polypropylene, polyester, polyamide, polyvinyl chloride, polyvinylidene chloride or the above plastic foam, hard boards, particle boards, chips such as plywood may be used alone or in combination of two or more.

As the binder used for binding the above fibers, for example, phenol resin, urea resin, melamine resin, urethane resin, epoxy resin, acrylic resin, polyethylene, polypropylene, starch, modified starch such as etherified starch, Synthetic resin binder such as rosin or natural resin binder, or urethane prepolymer, epoxy prepolymer, phenol prepolymer, urea prepolymer, melamine prepolymer, acrylic oligomer, polyvalent isocyanate, prepolymer such as acrylic monomer, oligomer, monomer Synthetic resin precursors such as Two or more of the above binders may be mixed. The binder is usually provided in the form of powder, liquid, solution, emulsion or the like, and the amount of the binder added to the fibers is usually about 10 to 50% by weight as solid content. However, the addition amount should be appropriately adjusted depending on the physical properties required for the product, and the above range does not limit the present invention.

[0009]

In the present invention, a molding material (4) made of a mixture of fibers and a binder is used to form an inner mold (2) and an outer mold of a molding die (1).
Between (3) and (3), the final density is in the range of 12 g / l to 50 g / l. Then, the molding material (4) is sprayed with a medium for curing or drying the binder from the porous surfaces (2A, 3A) of the inner mold (2) and / or the outer mold (3). 4) Cure and / or dry the binder inside. Therefore, since it is not necessary to apply a press for increasing the compression ratio in order to cure and / or dry the binder, a molded product having a density in the range of 12 g / l to 50 g / l, which is similar to that of polystyrene foam (5) Is easily obtained.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described with reference to FIGS. The molding die (1) shown in the figure consists of an inner die (2) and an outer die (3), and the die surface (2A) of the inner die (2) is porous, and the inner die (2) The medium introduction port (2B) is in contact with. The outer mold
The mold surface (3A) of (3) is made porous, and the suction path (3B) to which suction means such as a suction pump, a suction fan, and an ejector (not shown) are connected is connected to the inside of the outer mold (3). And
Further, the molding material supply path (3C) extended from the bottom of the mixing tank (6) is connected to the mixing tank (6), and the mixing tank (6) is equipped with an agitator (6A).
A blow pipe (7) for injecting compressed air toward the inside of the outer mold (3) is connected near the part where the outer mold (3) of C) is connected. For molding the fiber molding (5) in the molding die (1), a mixing tank (6) is composed of a waste paper pulp mixture in which 10% by weight of etherified starch and 10% by weight of water are mixed as a binder. The material (4) is prepared, and as shown in FIG. 1, the inner mold (2) is lowered into the outer mold (3) to maintain a predetermined space, and pressurized air is blown from the blow pipe (7) to the inner mold (3). It is sprayed toward the space (8) between the outer mold (2) and the outer mold (3), and the suction path (3B) is used to blow the porous mold surface (3
The inside of the space (8) is sucked through A), and the molding material is introduced into the space (8) between the inner mold (2) and the outer mold (3) as shown in FIG.
Fill (4). At this time, the pressure of the compressed air and the suction pressure are adjusted so that the density of the final molded product is 25 g / l,
Then, the blowing of the pressure air from the blow pipe (7) is stopped and the medium introduction port (2B) is inserted into the inner mold (2) from the medium introduction port (2B).
The molding material (4) was introduced from the porous mold surface (2A) by introducing hot air at 0 ° C.
Spray on. The hot air passes through the inside of the molding material (4) to evaporate the water contained in the molding material (4), dry and cure the molding material (4), and the hot air blows the lower mold (3 (3) is sucked into the suction pipe (3B) through the porous surface (3A), and thus the molded product (5) is molded. After molding the molded product (5), raise the inner mold (2) to open the mold (1),
Remove the molded product (5) from inside (3). Thus, a panel-shaped molded product (5) having a density of 25 g / l which can be used for an insulation board as shown in FIG. 3 is manufactured.

A second embodiment of the present invention will be described with reference to FIGS. The molding die (11) shown in the figure consists of an inner die (12) and an outer die (13), the die surface (12A) of the inner die (12) is made porous, and the inner die (12) A suction path (12B) connected to a suction means such as a suction pump or an ejector is connected to the outer mold (13A), and the mold surface (13A) of the outer mold (13) is made porous. The medium inlet (13B) communicates with the inside of 13). As shown in FIG. 4, the outer mold (13) is filled with a molding material (14) made of a recycled fiber mixture in which 30% by weight of a phenol resin is mixed as a binder, and as shown in FIG. ) Is lowered and the molding material (14) is lightly pressed between the inner mold (12) and the outer mold (13). The press pressure at this time is adjusted so that the final density is 40 g / l, and the outer mold (13)
Hot air at 180 ° C. is introduced into the inside from the medium introduction port (13B), and is blown onto the molding material (4) from the porous mold surface (13A).
The hot air passes through the inside of the molding material (14) and the molding material (1
4) Harden the phenolic resin contained in the inner mold (12)
It is sucked into the suction pipe (12B) through the porous surface (12A), and thus the molded product (15) is formed. Molded product (1
After molding 5), the inner mold (12) is raised to open the molding mold (11), and the molded product (15) is taken out from the outer mold (13). In this way, a density of 40 g that can be used for packaging containers such as those shown in FIG.
/ L box-shaped mold (15) is produced.

When water is not added to the molding material (4) in the first embodiment other than the above-mentioned embodiments, water vapor is blown out from the porous mold surface (2A) of the inner mold (2) to form the molding material (4). The waste paper pulp may be bound by swelling the etherified starch as a binder contained in (1). in this case,
Drying may be performed in the molding die (1) by blowing hot air and then blowing hot air. Further, in the second embodiment, the phenol resin curing catalyst (acid or alkali) contained in the molding material (14) may be mixed with hot air and blown out.

[0013]

Therefore, in the present invention, by using fibers as a molding material, a molded product having a density similar to that of polystyrene foam can be easily obtained.

[Brief description of drawings]

 1 to 3 show a first embodiment of the present invention.

FIG. 1 is an explanatory cross-sectional view before molding

FIG. 2 is an explanatory cross-sectional view after molding

FIG. 3 is a perspective view of a molded product. FIGS. 4 to 6 show a second embodiment of the present invention.

FIG. 4 is an explanatory cross-sectional view before molding

FIG. 5 is an explanatory cross-sectional view after molding

FIG. 6 is a perspective view of a molded product.

[Explanation of symbols]

 1,11 Mold 2,12 Inner mold 3,13 Outer mold 2A, 3A, 12A, 13A Porous mold surface 4,14 Molding material 5,15 Molded product

Claims (4)

[Claims] 1. A porous molded body obtained by binding fibers with a binder to form a desired shape, and having a density of 12 g / l to 5
Fiber molding characterized by being in the range of 0 g / l 2. The fiber molding according to claim 1, wherein the fiber is waste paper pulp. 3. A molding die comprising an inner die and an outer die, wherein the die surface of the outer die and / or the inner die is porous, and fibers are provided between the inner die and the outer die of the die. Molding material consisting of a mixture with a binder, the final density of which is 12 g / l to 50 g
The binder of the molding material is sprayed onto the molding material with a medium such that the mixture is filled to be 1 / l and the curing and / or drying of the binder is performed from the porous mold surface of the inner mold and / or the outer mold. A method for producing a fiber molding, which comprises curing and / or drying 4. The method for producing a fiber molding according to claim 3, wherein the fiber is waste paper pulp.