JPH073594A - Method for producing flame-retardant felt for molding - Google Patents

Abstract

PURPOSE:To continuously, extremely effectively and easily obtain the felt for moldings without using a special equipment by homogeneously mixing a powdery flame retardant with rag cotton comprising fiber refuse or with a fleece comprising the rag cotton, and subsequently heating the mixture. CONSTITUTION:Rag cotton comprising cut fiber refuse is homogeneously mixed with a powdery flame retardant (e.g. a phosphate) and a binder such as a phenolic resin, formed into a fleece having an uniform thickness with a fleece- producing machine, thermally melting the formed fleece and subsequently solidifying the fleece, thus effectively, easily and continuously producing the flame- retardant felt for moldings without requiring the conventional large installation such as an immersion tank or a centrifugal dehydrating and thermally drying device.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat-insulating and sound-absorbing material used for automobile interior materials and the like, and a method for producing a molding felt having flame retardancy.

[0002]

2. Description of the Related Art Conventionally, as a low-cost manufacturing method of molding felts, fiber scraps (sewn scraps) made of synthetic fibers such as cotton or polyester are made into chips or subdivided, and treated with anti-hair treatment, Add a binder (binder) such as a thermosetting resin, mix (spin) evenly, and further open the fiber to form a fleece with a predetermined thickness, and heat it to obtain a felt for molding. Such technology is known.
By the way, in order to keep the molding felt to have a predetermined flame retardance (non-flammability), it is necessary to hit a flame retardant such as phosphoric acid. After that, that is, in the state of anti-cotton. This flame-retardant treatment involves accommodating the cotton wool in a wire mesh container and immersing it in an aqueous solution containing the flame-retardant for a predetermined time to allow the flame-retardant to penetrate. Therefore, in the case of this method, the dipped fluff is pulled up, sufficiently dehydrated by a centrifuge, etc., and the fluff is dried through a heating and drying step, and a binder is applied to the fluff ( Blending), a fleece having a predetermined thickness, and a molding felt (hereinafter, also referred to as molding felt or simply felt) having flame retardancy by heating (see FIG. 3). Then, if necessary, the felt was hot pressed to melt and solidify the binder to form a hard board (member), which was provided for each purpose.

[0003]

In the above-mentioned prior art, since the so-called cotton is subjected to the flame-retardant treatment, the treatment is carried out by a special large-sized dipping tank capable of such treatment, dehydration, or a heating and drying device. Although it cannot be done without a factory having equipment, the factory having such equipment was usually limited to a dyeing factory. Therefore, conventionally, the fluff-free cotton is transported to the dyeing factory after being fluffed and subjected to the flame-retardant treatment there.
Therefore, there is a problem in that the felt cannot be produced from the fluff in a continuous process, and the production efficiency is extremely poor. Moreover, in the dyeing factory, because of the flame-retardant treatment in the state of cotton, it takes a long time to dry (dehydrate, heat) after the treatment, and such a process consumes a lot of energy. there were. On the other hand, as seen from the felt forming process, since it is waiting for anti-cotton (work-in-process material) that has been subjected to flame-retardant treatment, manufacturing cannot be facilitated, and together with the above problems, the manufacturing cost rises significantly. Was invited. Therefore, the present invention solves the problems caused by the conventional manufacturing method,
It is intended to provide a manufacturing method that enables efficient production of materials such as fiber waste from the production of flame-retardant molding felt in a continuous process, improving production efficiency and significantly reducing costs. To aim.

[0004]

In order to achieve the above-mentioned object, the first means of the method for producing a molding felt having flame retardancy according to the present invention is a fiber material made of chips such as fiber scraps. In a method for producing a felt for molding by binding fibers with a binding agent that is applied by heating, Flame retardancy is imparted by mixing powdered flame retardant with cotton. The second means is to fluff a fibrous material, which is formed into chips such as fiber scraps, into fluff and to use this fluff as fleece,
Then, in the method for producing a molding felt by binding fibers with a binding agent applied by heating, it is difficult to sprinkle a powdery flame retardant on the upper surface of the fleece almost uniformly. It is intended to impart flammability.

In the first means, the anti-wool is imparted with flame retardancy by mixing it with a powdery flame retardant. Therefore, it is difficult to immerse the anti-wool in a solution of the flame retardant. As in the case of the flame treatment, the flame-retardant treatment can be performed without transporting it to a dyeing factory or the like having a special facility therefor, and without requiring processes such as dehydration by centrifugation and heat drying. Further, in the second means, since the powdery flame retardant is sprinkled almost evenly on the upper surface of the fleece to impart flame retardancy, the flame-retardant treatment of the entire fleece conveys it to the heating step. It can be done in the process of doing.

[0006]

Embodiments of the present invention will be described in detail with reference to FIGS. 1 and 2. First, fiber waste made of cotton, polyester, or the like is cut (cut) into appropriate small pieces by a cutting machine (not shown) or the like. Then, this is put into a front fluff machine or a garnet machine (not shown) to open the fiber, and the fibers are sufficiently disentangled to obtain anti-wool (cotton-like) made of a collection of long and short fibers.

Next, the anti-wool cotton 1 thus obtained is fed into the hopper feeder 11 shown in FIG. 2 and placed on the production line. That is, the anti-wool cotton 1 is opened in the hopper feeder 11 and discharged onto the carrier 12 by a predetermined amount and sent to the next step. However, in the present example, the hopper 13 in the middle thereof contains the powdered (powdered) phenol resin as the binder and the powdered phosphoric acid as the flame retardant, which is uniformly mixed, and contains the mixed powder 2. Then, both the phenol resin and the phosphoric acid are set so as to be sprinkled in an appropriate amount on the fluff and approximately evenly. That is, in this example, the flame retardant treatment is performed simultaneously with the application of the binder. The amount of phenolic resin is set to about 20% by weight and the amount of phosphoric acid is set to about 30% by weight with respect to the unit weight of cotton wool. Then, this material is fed into the fleece making machine 14 and sufficiently mixed until uniformly mixed. In the fleece manufacturing machine 14, the fibers are further finely opened, the binder and the flame retardant are mixed more uniformly, and the fleece 3 having a uniform thickness is discharged onto the conveyor 22 and conveyed at a predetermined speed. .

Thus, the anti-wool becomes a fleece having a uniform flame retardant property, and is passed between the set pressure rollers 15 to have a predetermined thickness and passed through the heating furnace 16 by the conveyor 32. . In the heating furnace 16, the fleece 3 is continuously melted and solidified from both sides of the fleece 3 to a predetermined depth by the hot air (200 ° C.) so that the binder and flame retardant are bonded to the fibers. So-called bulky felt 4 that is conveyed as desired and has desired flame retardancy
Will be discharged. Thus, a felt product for molding which is used for an interior member of an automobile or the like is obtained by cutting this into an appropriate shape and size according to the application.

The felt 4 thus obtained is used as a felt for thermoforming in the next step of 250-2.
By hot pressing at 60 ° C., a hard board having flame retardancy is obtained. In this case, the binder is applied in an amount of about 30 to 40% by weight based on the weight of the fluff. Further, in this case, the inside of the felt may be in a non-solidified or unplasticized state in the heating step in manufacturing the felt. This is because only the surface fibers need to be bound to the extent that they can be handled.

In the above embodiment, the hopper feeder 11
The powder is sprinkled with a powdered flame retardant in the state of anti-wool before being discharged from the fleece making machine 14 and is subjected to the flame retardant treatment by sprinkling the flame retardant in the state of the fleece. You can also Further, in the above-mentioned embodiment, the flame retardant is mixed with the binder in a predetermined ratio and sprinkled on the cotton wool as a mixed powder, so that the process can be simplified. However, it suffices that the flame retardant treatment is performed uniformly and to a predetermined degree of flame retardancy. Therefore, the mixing of the flame retardant may be performed separately from the application of the binder. The amount of flame retardant (powder) may be set so that the flame retardant treatment is appropriately performed according to the degree of flame retardancy (set value) required for each application of the product. Phosphoric acid was used as the flame retardant in the above examples, but in addition to this, polyphosphoric acid, phosphoric acid ester, aluminum hydroxide, borax, boric acid, etc., which are used as flame retardants, have high stability as powder. If so, an appropriate one (organic or inorganic) can be used. However, it is preferable that the particle size of the powder is as small as possible for homogenizing the flame retardancy, and the mesh size is 200 or more (average particle size of 0.
075 mm or less) is preferably used. As the binder, a thermosetting resin other than a phenol resin or a thermoplastic resin can be used.

[0011]

As is apparent from the above description, in the first means of the present invention, flame retardancy is imparted to the anti-wool by mixing the powdered flame retardant. As in the case of immersing anti-cotton in a flame retardant solution for flame-retardant treatment, transport it to a dyeing factory that has special equipment for it, or perform an independent drying process such as dehydration by centrifugation and heat drying. Flame-retardant treatment can be performed without need. Further, in the second means, the powdery flame retardant is sprinkled almost evenly on the upper surface of the fleece to impart flame retardancy. Therefore, the entire flame retardant treatment of the fleece is performed in the conveying process to the heating step. it can. That is, in the present invention, the flame-retardant treatment can be continuously and efficiently performed in the process of conveying anti-wool or fleece from the anti-wooling process to the heating process. Therefore, the molding felt having flame retardancy can be efficiently manufactured, and the manufacturing cost can be significantly reduced.

[Brief description of drawings]

FIG. 1 is a block diagram showing steps of a manufacturing method according to the present invention.

FIG. 2 is an explanatory view of a production line after a flame-retardant treatment for explaining the production method according to the present invention.

FIG. 3 is a block diagram showing a conventional manufacturing process of a molding felt having flame retardancy.

[Explanation of symbols]

 1 Anti-wool 2 Mixed powder of binder and flame retardant 3 Fleece 4 Felt for molding 11 Hopper feeder 12, 22, 32 Conveyor 13 Hopper 14 Fleece making machine 15 Pressure roller 16 Heating furnace

Claims (2)

[Claims] 1. A fiber material made of chips such as fiber scraps is fluffed to give fluff, and this fluff is used as a fleece.
Then, in the method for producing a molding felt by binding fibers with a binder that is applied by heating, a flame retardant is imparted by mixing a powder flame retardant with the anti-wool cotton. A method for producing a molding felt having flame retardancy, comprising: 2. A fiber material made of chips such as fiber scraps is fluffed to give fluff, and this fluff is used as a fleece.
Then, in the method for producing a molding felt by binding fibers with a binding agent applied by heating, it is difficult to sprinkle a powdery flame retardant on the upper surface of the fleece almost uniformly. A method for producing a molding felt having flame retardancy, which is characterized by imparting flammability.