JPH09225916A - Bond molding of granular material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a low density, soft molding including an air layer based on a granular material as a raw material. SOLUTION: A granular material with an average grain size of about 8mm containing a urethane granule or fiber and a 5-10mm fibrous composite binder (melting point: 110 deg.C and 240 deg.C) are mixed using a mixer 1, and this mixture of a thickness larger than specified is supplied onto a molding die K by a fiber laminator 3. An excess mixture is removed by a thickness adjuster 4, then is heated to 150-180 deg.C in an oven 5 and thereby, the surface of the composite binder is melted. After that, the mixture is pressed by a cooling press 6 to be molded into a specified form, and at the same time, the molding is cooled by a cold air. In addition, the granular material is crosslinked with the composite binder to secure the maintenance of the form of the molding. The molding consists of numerous granular materials crosslinked with the fibrous composite binder, and is of the soft quality and low density including an air layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of joining granular materials into a predetermined shape, and relates to a technique suitable for use in manufacturing soundproofing materials, heat insulating materials and the like.

[0002]

2. Description of the Related Art As a technique for combining granular materials such as granular urethane into a predetermined shape, a technique of spraying a liquid binder on the granular material, then adding steam to heat and pressurizing with a mold is known. Are known.

[0003]

Since the granular materials are bonded to each other in the molded product molded by using the above-mentioned technique, only a hard product having a relatively high density can be molded. For example, a soundproof material or a heat insulating material. A soft material having a low density including the required air layer had a problem that it could not be molded.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object thereof is to provide a manufacturing method capable of manufacturing a low-density soft molded article containing an air layer by using a granular material. It is in.

[0005]

Means for Solving the Problems The following technical means is adopted for the method of bonding and molding granular materials according to the present invention. [Means for Claim 1] The method for bonding and molding a granular material is (a)
A mixing step of mixing a granular material having a granular shape and a composite binder having a fibrous shape and having a different melting point; and (b) supplying the mixture mixed in the mixing step onto a mold in a thickness larger than a predetermined thickness. And (c) adjusting the thickness of the mixture supplied on the mold to the predetermined thickness by removing a portion thicker than the predetermined thickness from the mixture supplied on the mold. A thickening step, (d) a heating step of heating the mixture adjusted in the thickness adjusting step, and (e) a molding step of pressurizing the mixture heated in the heating step into a predetermined shape. Prepare

[Means for Claim 2] In the method for binding and molding a granular material according to claim 1, a fixed amount of the mixture mixed in the mixing step is introduced to the on-die supply step by a predetermined amount within a predetermined time. It is characterized by including a step.

[Means for Claim 3] In the method for bonding and molding a granular material according to claim 1, among the molded products molded in the molding step, unnecessary substances cut by a cutter or the like are defibrated and defibrated. It is characterized by comprising a re-defibration step for reusing the defibrated material as a raw material.

[Means for Claim 4] In the method for bonding and molding a granular material according to any one of Claims 1 to 3, the mixture is supplied from above in the above-mentioned mold supplying step, and the mixture is supplied. Using a fiber stacker that supplies a mixture thicker than the predetermined thickness above the mold by providing a shooter that guides the mixture above the mold, the shooter being displaced above the mold. Is characterized by.

[Means of Claim 5] In the method for bonding and molding a granular material according to any one of Claims 1 to 4, the thickness adjusting step is arranged so that the upper side of the mold can pass therethrough, and a scraping portion is provided. The rotating body is provided with a rotating body, and when the rotating body passes above the mold, the scraping portion rotates and removes a portion of the mixture supplied onto the mold, the portion being thicker than the predetermined thickness. It is characterized by using a thick machine.

[Means for Claim 6] In the method for binding and molding a granular material according to any one of claims 1 to 5, the fiber length of the composite binder is 0.5 of the diameter of the granular material.
It is characterized in that it is provided within a range of up to 2.0 times.

[Means for Claim 7] In the method for binding and molding a granular material according to claim 6, the mixing step is performed within a range of 0.5 to 2.0 times the diameter of the granular material and the granular material. Using a mixer provided with a mixing container into which the provided composite binder is charged, and a rotating blade rotating in the mixing container, the granular material and the composite binder charged into the mixing container are The blade is directly agitated and agitated by the airflow generated by the rotation of the rotary vane.

[0012]

Effects of the Invention and Effects of the Invention

[Operation and Effect of Claim 1] First, in the mixing step, the granular material and the composite binder are mixed. Next, in the on-die supplying step, the mixture is put on the die so as to be thicker than a predetermined thickness. Then, in the thickness adjusting step, the mixture in a portion thicker than a predetermined thickness is removed. Then, in the heating step, the thickness of the mixture is heated on the mold, and in the molding step, the heated mixture is pressurized to form a predetermined shape.

By using the above-mentioned manufacturing method, each granular material is crosslinked and bonded by the composite binder to be molded into a predetermined shape. As described above, since the granular materials are bonded through the fibrous composite binder by using the method for bonding and molding the granular material, the molded product molded by the above manufacturing method is molded by the conventional technique. As compared with the molded product according to the present invention, the molded product is a low-density soft molded product including an air layer.

[Operation and Effect of Claim 2] In the method for binding and molding a granular material, by providing a fixed amount supply step of guiding the mixture mixed in the mixing step to the on-die supply step by a predetermined amount within a predetermined time, In the on-mold supplying step, it becomes easy to put the mixture on the mold thicker than a predetermined thickness, and at the same time, the mixture can be put thicker than the predetermined thickness on the mold.

[Operation and effect of claim 3] In the method of bonding and molding a granular material, among the molded products molded in the molding step, unnecessary substances cut by a cutter or the like are defibrated, and the defibrated defibration is performed. Since the fibrous material is reused as a raw material, it is possible to eliminate the problem that waste is generated from the manufacturing process using the method of bonding and molding the granular material.

[Operation and Effect of Claim 4] The on-die feeding step in the method for binding and molding granular materials comprises a shooter to which the mixture is fed from above and which guides the mixture onto the die.
A stacker that supplies the mixture to the mold with a thickness greater than a predetermined thickness by shifting the shooter with respect to the mold is used. As described above, by using the fiber feeder in the on-mold supply step, the mixture can be stably supplied onto the mold with a thickness larger than a predetermined thickness.

[Operation and Effect of Claim 5] The thickness adjusting step in the method of bonding and molding granular materials is provided with a rotating body which is arranged so that the upper side of the mold can pass therethrough, and the scraping portion rotates, and the upper side of the mold is scraped. A thickness adjuster is used that removes a portion thicker than a predetermined thickness in the mixture supplied onto the mold by allowing the portion to pass while rotating. In this way, the mixture on the mold can be of a given thickness and the density of the resulting molding can be kept at a suitable density.

[Operation and Effect of Claim 6] The fiber length of the composite binder used in the method of bonding and molding a granular material is
By providing it within the range of 0.5 to 2.0 times the diameter of the granular material, the mixing property of the granular material and the composite binder becomes high, the granular material and the composite binder can be uniformly mixed, and molding is performed. The quality of things can be improved.

[Operation and Effect of Claim 7] The mixing step in the method of binding and molding a granular material is carried out by adjusting the diameter of the granular material to 0.
A composite binder provided within a range of 5 to 2.0 times,
A mixer provided with a mixing container into which the granular material is put and a rotary blade rotating in the mixing container is used. And
The granular material and the composite binder charged in the mixing container are directly agitated by the rotary blades and agitated by the air flow generated by the rotation of the rotary blades. As a result, the mixing properties of the granular material and the composite binder are improved, the granular material and the composite binder can be mixed in a short time without unevenness, and the quality of the molded product to be molded can be improved.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION Next, a method of bonding and molding a granular material according to the present invention will be described based on an embodiment shown in the drawings. [Structure of Embodiment] FIGS. 1 to 3 show an embodiment in which the present invention is adopted. FIG. 1 is a schematic side view of a production facility line for manufacturing a molded product by binding granular materials, and FIG. 3 is a schematic side view of the material transporter used in the step, and FIG. 3 is a schematic front view of the thickness adjuster used in the thickness adjusting step.

A production facility line for manufacturing a molded product (for example, a sound insulating material for a car, a heat insulating material, etc.) by combining granular materials serves as a mixer 1 which performs the function of a mixing step and a function of a fixed amount supply step. The bale feeder 2, the stacking machine 3 that performs the function of the on-die supply process, the thickness adjuster 4 that performs the function of the thickness control process, the oven 5 that performs the function of the heating process, and the cooling press 6 that performs the function of the molding process. And a take-out device 7 for taking out the manufactured molded product, and a re-defibrating defibrating machine 8 which functions as a re-defibrating step.

The mixer 1 mixes a granular material having a granular shape with a fibrous composite binder having a different melting point. In this embodiment, the granular material is mainly urethane.
It uses raw materials containing fibers.

The composite binder is a fibrous material in which a low-melting-point binder is provided around a high-melting-point fibrous body, and is in the range of 0.5 times to 2.0 times the diameter of the granular material used as a raw material. It is provided inside. Specifically, for example, if the average particle diameter of the granular material used as the raw material is 8 mm, the composite binder having a diameter of 4 to 16 mm is used.

In this embodiment, the average particle size of the granular materials is about 8 mm, and the length of the composite binder is 5-10.
By setting the thickness to mm, the stirring property of the composite binder and the granular material is improved. Further, in this example, as the composite binder, a polyester having a melting point of 110 ° C. was provided around the polyester having a melting point of about 240 ° C.
A 0 mm composite polyester binder is used.

The mixer 1 is a cylindrical mixing container 1a in which a granular material and a composite binder having a length of 5 to 10 mm are charged.
And a plurality of rotary blades 1 rotating in the mixing container 1a
b. The rotary blade 1b rotates in a state where there is a clearance between the rotary blade 1b and the inner wall of the mixing container 1a, and the granular material and the composite binder put in the mixing container 1a directly hit the rotary blade 1b, In addition to being stirred in the clearance, it is also stirred by the air flow generated by the rotation of the rotary blade 1b. When the granular material and the composite binder are agitated by the mixer 1, the agitated mixture of the granular material and the composite binder is discharged onto the lower belt conveyor B and supplied to the bale feeder 2.

The inlet 1c for the granular material and the composite binder in the mixer 1 is provided at the upper position,
As a means for charging the granular material and the composite binder into the charging port 1c, a material carrier 9 is used as shown in FIG. This material carrier 9 manually or automatically charges the granular material and the composite binder into the charging container 9a at a fixed ratio, and transfers the charging material in the charging container 9a by the carrier means 9b to the charging port 1c of the mixer 1. It leads to.

The bale feeder 2 is agitated by the mixer 1.
The mixed mixture is guided to a laminating machine by a predetermined amount within a predetermined time. Specifically, the mixture conveyed by the belt conveyor B is pooled in a corner section C, and a fixed amount of the pooled mixture is added. It is scraped up and supplied to the next step.

The fiber stacker 3 puts the mixture supplied from the bale feeder 2 on the mold K with a predetermined thickness (a predetermined thickness determined by the upper surface of the mold K and the lower end of the blade roller 4c described later). It is supplied thickly. Here, the mold K to which the mixture is supplied is one in which an air flow can easily pass in the vertical direction, such as a mesh shape or a large number of punched holes formed. In addition, the mold K is
It is provided so as to perform intermittent operation in which movement and stop are repeated.

The laminating machine 3 of this embodiment is provided with a swing shooter 3a for feeding the mixture onto the mold K. The swing shooter 3a is supplied with the mixture conveyed from the bale feeder 2 from above and guides the mixture onto the mold K arranged from the lower end to the lower side. When the mold K is stopped, the lower end of the swing shooter 3a is moved. By swinging and moving above the mold K, the mold K
The mixture is supplied on top of the above to be thicker than a predetermined thickness.

The thickness adjuster 4 removes a portion thicker than a predetermined thickness from the mixture supplied onto the mold K by the laminating machine 3 and adjusts the thickness of the mixture supplied onto the mold K to a predetermined thickness. It is a thing. As shown in FIG. 3, the thickness adjuster 4 of the present embodiment includes suction means 4a for sucking air from the lower part of the mold K, and along the rails 4b provided above the mold K, A plurality of blade rollers 4c (corresponding to a rotating body) capable of rotating and passing through the upper side are provided.

Each blade roller 4c is provided with a plurality of scraping blades 4d (corresponding to a scraping portion) around the blade roller 4c, and the scraping blades 4d rotate to rotate the upper side of the mold K so that the mixture hitting the scraping blades 4d is removed. Remove from above mold K. The scraping blade 4d is rotated in the direction in which the mixture is scraped.

By sucking air from the lower part of the mold K by the suction means 4a, the density of the mixture placed on the mold K can be maintained at an appropriate density, and the scraping blade 4d is rotated to rotate it. The problem that the mixture is removed excessively can be prevented. The scraped mixture is transported to the pool of the bale feeder 2 by a transport unit (not shown).

The oven 5 heats the mixture adjusted by the thickness adjuster 4 to melt only the low melting point binder of the composite binders. In this embodiment, the center polyester (melting point about 240 ° C.) is used. Is heated to, for example, 150 to 180 ° C. so that the surrounding polyester (melting point: about 110 ° C.) is melted without melting the above. The oven 5 of this embodiment heats the mixture on the mold K with hot air, and is provided so that the hot air passes through the mixture on the mold K by a plurality of hot air circulation means 5a. There is.

The cooling press 6 presses the mixture heated in the oven 5 by the press 6a to form it into a predetermined shape. The mixture pressed by the press 6a has a finished product surface and is molded. The thickness is determined. Further, the cooling press 6 includes a cooling unit (not shown) that sends cold air to the pressurized mixture, applies cold air to the molded product whose pressure has been determined and whose thickness has been determined, and cools the binder by the cold air, thereby The low melting point binder of the composite binder adheres to the particulate material so that the composite binder crosslinks each particulate material. This results in the formation of a low density soft molding containing an air layer in which a large number of particulate materials are crosslinked by a large number of composite binders,
The shape of the molding is retained.

The molded product molded by the cooling press 6 is conveyed to the outside of the manufacturing equipment line by the take-out device 7. The molded product carried out of the unloading device 7 is cut into a predetermined shape by a cutter or the like (not shown).

The defibrating machine 8 for recycling crushes and defibrates the surrounding unnecessary material (cutting edge material) cut by a cutter or the like, and restores the defibrated defibrated material as a raw material. In the example, the defibrated material restored to the raw material is supplied to the bale feeder 2 for reuse. The recycling defibrating machine 8 includes a roller 8a for sandwiching an unwanted material and a rotary needle 8b for rotating a large number of needles for defibrating the unwanted material held and supplied by the roller 8a.

[Effects of the Embodiment] In the production facility line of this embodiment, a large number of granular materials such as urethane and fibers are used.
Since a molded product is manufactured by crosslinking with a large number of fibrous composite binders, the manufactured molded product can be a low-density soft molded product containing an air layer. As described above, since the molded product is a low-density soft product including an air layer, a sound insulating material, a heat insulating material and the like can be manufactured by using the granular material by using the manufacturing equipment line of this embodiment.

Further, in the production equipment line of this embodiment, waste is produced from the production equipment line because the unnecessary material cut by a cutter or the like is defibrated and the defibrated material is reused. There is no.

[Modification] In the above embodiment, the mold K is provided so as to perform the intermittent operation, but it may be provided so as to continuously move. Also, an example in which the shooter 3a shakes its head is shown,
The shooter 3a may be fixedly provided, and by supplying the mixture onto the moving mold K, the mixture may be provided above the mold K with a thickness larger than a predetermined thickness.

In the above embodiment, the rotary body of the thickness adjuster 4 is the type K.
Although an example in which the rotating body rotates in parallel with the mold K has been shown, the rotating body may rotate perpendicularly to the mold K to scrape off the excess mixture on the mold K. Also, an example has been shown in which the rotating body moves over the stopped mold K to scrape off the excess mixture, but the rotating body may scrape off the excess mixture on the moving mold K. good.

[Brief description of drawings]

FIG. 1 is a schematic side view of a manufacturing equipment line.

FIG. 2 is a schematic side view of a material transporter.

FIG. 3 is a schematic front view of a thickness adjuster.

[Explanation of symbols]

 1 Mixer (Fulfilling the mixing process) 1a Mixing container 1b Rotating blades 2 Bale feeder (Fulfilling the constant amount feeding process) 3 Stacking machine (Fulfilling the mold feeding process) 3a Shooter 4 Thickening machine (Fulfilling the thickening process) 4c Blade roller (rotating body) 4d Scraping blade (scraping part) 5 Oven (performing the heating process) 6 Cooling press (performing the molding process) 7 Unloading device 8 Disentanglement machine for regeneration (performing the regeneration defibration process) K type

 ─────────────────────────────────────────────────── ─── Continued Front Page (72) Inventor Taketsugu Sugiguchi 5-21-11 Chiyoda, Naka-ku, Nagoya, Aichi Prefecture Nakagauchi Co., Ltd. (72) Mitsumasa Kanda 5--21, Chiyoda, Naka-ku, Nagoya, Aichi Prefecture No. 11 Chugai Co., Ltd. (72) Inventor Takuji Kajiwara 1 Toyota Town, Toyota City, Aichi Prefecture Toyota Motor Co., Ltd. (72) Inventor Ikuji Tsujita 1, Toyota Town, Aichi Prefecture Toyota Motor Co., Ltd.

Claims (7)

[Claims] 1. A mixing step of mixing (a) a granular material having a granular shape and a fibrous composite binder having a different melting point, and (b) the mixture mixed in the mixing step is placed on a mold. A step of supplying on the mold thicker than a predetermined thickness, and (c) removing a portion thicker than the predetermined thickness from the mixture supplied on the mold to remove the mixture supplied on the mold. A thickness adjusting step of adjusting the thickness to the predetermined thickness; (d) a heating step of heating the mixture adjusted in the thickness adjusting step; and (e) a predetermined pressure applied to the mixture heated in the heating step. And a step of forming into a shape, a method of bonding and forming a granular material. 2. The method for bonding and molding granular materials according to claim 1, further comprising a fixed amount feeding step of guiding the mixture mixed in the mixing step to the on-mold feeding step by a predetermined amount within a predetermined time. A method for bonding and molding a granular material characterized. 3. The method for binding and molding a granular material according to claim 1, wherein among the molded products molded in the molding step, unnecessary substances cut by a cutter or the like are defibrated and the defibrated defibrated product is defibrated. A method for binding and molding a granular material, which comprises a re-defibration step for reusing the above as a raw material. 4. The method for bonding and molding a granular material according to claim 1, wherein in the on-die feeding step, the mixture is fed from above.
A shooter for guiding the supplied mixture onto the mold arranged below is provided, and the shooter is displaced above the mold to supply the mixture onto the mold in a thickness larger than the predetermined thickness. A method of bonding and molding a granular material, characterized by using a stacking machine. 5. The method for bonding and molding a granular material according to claim 1, wherein in the thickness adjusting step, a rotor is arranged so that the upper side of the mold can pass therethrough, and a scraping portion rotates. Using a thickness adjuster in which the scraping unit rotates and removes a portion thicker than the predetermined thickness in the mixture supplied onto the mold by passing the rotating body over the upper side of the mold. And a method of bonding and molding a granular material. 6. The method for binding and molding a granular material according to any one of claims 1 to 5, wherein the fiber length of the composite binder is within a range of 0.5 to 2.0 times the diameter of the granular material. A method for bonding and molding a granular material, which is provided. 7. The method for bonding and molding a granular material according to claim 6, wherein the mixing step includes the granular material and the composite provided within a range of 0.5 to 2.0 times the diameter of the granular material. Using a mixer having a mixing container in which a binder is charged and a rotating blade rotating in the mixing container, the granular material and the composite binder charged in the mixing container are directly contacted with the rotating blade. A method for bonding and molding a granular material, which is agitated and also agitated by an air flow generated by the rotation of the rotary blades.