JPH10139891A - Plate-like product or molding product and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a plate-like product or molding product, having a small changing ratio of thickness in water-absorbing state, excellent in strength, mois ture permeability and workability and useful for house interiors, etc., by attaching an amino resin and a curing agent to a specific fiber mat and subjecting the fiber mat to compression molding. SOLUTION: A defiberized palm fiber such as oil palm fiber is as necessary, mixed with a vegetable natural fiber such as linen fiber or bamboo fiber to form a fiber mat 2 and as necessary a woven or knitted fabric composed of vegetable natural fiber, a nonwoven fabric or, a sheet-like material 4 comprising thin sheet is arranged at least on one surface and/or in the interior of the fiber mat 2 and preferably 5-100wt.% (based on palm fiber) amino resin such as urea resin or melamine resin and a curing agent such as ammonium chloride are attached to the fiber mat and the fiber mat is subjected to compression molding to provide the objective plate-like product 3 or molding product having 0.35-0.6g/cm<3> density. Furthermore, basis weight of the sheet-like material 4 is preferably 10-1,500g/cm<2> .

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plate-like body similar to a wood fiberboard and a molded body obtained by molding the same into a predetermined shape, and particularly exhibits excellent performance in both moisture permeability and strength. The present invention relates to a plate-like body or a molded body having a small thickness change rate in a water-absorbing state.

[0002]

2. Description of the Related Art Conventionally, when a fiber-based heat insulating layer such as glass wool is formed in a wall of a wooden house, a ventilation layer is formed between the outer wall and the heat insulating layer in order to release water vapor in the room to the outside. Thus, the water vapor in the room that has passed through the heat insulating layer diffuses from under the eaves to the outside through the ventilation layer. In that case, a windproof layer that separates the ventilation layer and the heat insulating layer is required. The windproof layer has a function of retaining the heat insulating layer, but must have excellent moisture permeability so that water vapor can be smoothly transmitted to the ventilation layer.

[0003] Conventionally, as a material for forming the windproof layer,
For example, polyethylene non-woven fabric has been used, but if glass wool or the like is used for the heat-insulating layer, the non-woven fabric swells and deforms due to the expansion force of the heat-insulating layer, narrowing and sometimes closing the ventilation layer. This is particularly likely to occur when a large amount of glass wool or the like is packed in a cold region (see the standard specifications for construction work, JASS24 insulation work (edited by the Architectural Institute of Japan)). Therefore, among the fiberboards, a sheathing board, which is a kind of a soft fiberboard having relatively small density and air permeability, is applied to the outside of the heat insulating layer, and the end side thereof is a structure such as a pillar, a stud, a beam, a girder or a brace. By fixing to a material, a windproof layer having a certain strength is formed.

[0004]

However, even though the above-mentioned conventional sizing board can withstand the expansion force of the heat insulating layer,
It does not have enough strength to function as a structural face material itself. Therefore, the strength of the structural portion around the seasing board had to rely exclusively on the above-mentioned structural material other than the seasing board.

The present invention has been made in view of such a point, and a first object of the present invention is to use a natural vegetable fiber having a higher bonding strength with a resin than an artificial fiber. Assuming that, among them, palm fibers that form a large gap between thick fibers are collected, and by firmly fixing the fibers with curable resin, it has both excellent moisture permeability and high strength, and in the water absorbing state The object of the present invention is to provide a plate-like body or a molded body having a small thickness change rate. In addition, the manufacturing method is also proposed.

[0006] The second problem is that vegetable natural fibers, which have a better bonding strength with resin than artificial fibers, are used, and large gaps are formed between thick fibers. A woven fabric, a nonwoven fabric or a sheet made of flakes made of vegetable natural fibers having a proper tensile strength and a tensile elasticity, by collecting the coconut fibers to be surely fixed with a curable resin. An object of the present invention is to provide a plate-like body or a molded body having both excellent moisture permeability and high strength and having a small rate of change in thickness in a water-absorbing state, by integrating and reinforcing a shaped material with the curable resin. In addition, the manufacturing method is also proposed.

[0007]

Means for Solving the Problems The present inventors have conducted intensive studies in order to solve the above first problem, and have found that natural resins such as coconut fibers and the like can be obtained by using an amino resin and a curing agent as the curable resin. It has good affinity and permeability with the surface, forms an effective adhesive film on the fiber surface, exhibits excellent performance in both strength and moisture permeability, and has a small rate of change in thickness when absorbing water, and heat The inventors have found that the compression time can be reduced, and have reached the following invention. That is, the present invention relates to a plate-like body or a molded body obtained by adhering an amino resin and a curing agent to a fiber mat made of palm fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, if necessary, followed by compression molding. About.

Further, the present inventors have conducted intensive studies in order to solve the above second problem, and have used an amino resin and a curing agent as a curable resin, and at least one surface of a plate-like body or a molded body and / or By arranging a knitted woven fabric made of vegetable natural fibers, a nonwoven fabric or a sheet made of flakes inside, it has good affinity and permeability with natural fiber surfaces such as coconut fibers and effective bonding to fiber surfaces It has been found that a film is formed, and excellent performance is exhibited in both strength and moisture permeability. In particular, it has been found that the rate of change in thickness at the time of water absorption is small and the time for heating and compressing can be shortened. That is, the present invention relates to a knitted woven fabric, a nonwoven fabric, or a flake made of vegetable natural fibers on at least one surface and / or inside of a fiber mat made of palm fibers mixed with vegetable natural fibers such as hemp fiber and bamboo fiber as necessary. The present invention relates to a plate-like body or a molded body obtained by arranging a sheet-like material, adhering an amino resin and a curing agent thereto, and compression-molding the same.

Further, the present invention relates to the above-mentioned plate-like body or molded article using oil palm fiber as palm fiber. Furthermore, the present invention relates to the above-mentioned plate-like body or molded article using hemp cloth as a knitted fabric. Further, the present invention further comprises a fiber mat formed by mixing vegetable natural fibers such as hemp fiber and bamboo fiber, if necessary, and at least one surface and / or inside of the fiber mat comprises vegetable natural fiber as necessary. The present invention relates to a method for producing a plate-like body or a molded body in which a sheet-like body made of a knitted fabric, a nonwoven fabric, or a flake is arranged, an amino resin and a curing agent are adhered to these, and compression-molded.

[0010] The use of the plate-like body or molded article of the present invention may be, but not limited to, a windproof layer used for forming a ventilation layer on the outer wall of a house as described above. For example, home interior materials, interior base materials, roof base materials, ceiling materials, floor materials, floor base materials, tatami floors, architectural structural material heat insulating materials, sound absorbing materials, sound insulating materials, shock absorbing materials, cushioning materials, rims, etc. It can be used for all building material applications where plywood, glulam, particle board, etc. are used as building materials. In addition, concrete formwork materials, drainage culverts, ground stabilizing materials, civil engineering applications such as geotextiles, pallets, packaging materials applications, vehicle interior materials such as automobiles, interior base materials, exterior materials and vegetation mats, tree planting pots, and agricultural and horticultural applications. Can also be used.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION A plate-like body according to a first embodiment of the present invention comprises a fiber mat made of palm fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, if necessary, with an amino resin and a cured resin mat. By adhering the agent and compression molding, it has both excellent moisture permeability and high strength, and particularly has a small rate of change in thickness in a water-absorbing state.

The coconut fibers used in the present invention are coconut palm,
Oil palms, sago palms, date palms, sardines, nippa palms, sugar palms, pea palms, palms, palms,
Fibrous bark collected from palm plants such as black clogs,
Fibers such as petiole base fiber and mesocarp fiber, including fibers obtained by defibrating empty fruit clusters of oil palm. Also, a mixture of a plurality of types of coconut fibers is included.

Since coconut fibers have a large diameter of about 100 to 600 μm, when formed into a fiber mat, a gap having a size of, for example, about 100 μm to 5 mm, preferably about 200 μm to 3 mm, is formed between the fibers depending on the fiber packing density. It is formed. Therefore, the moisture permeability of the fiber mat is extremely good. Depending on the amount of the resin and the curing agent or the degree of compression during molding when the amino resin and the curing agent are adhered to the fiber mat and compression-molded, the size and the gap of the gap between the fibers of the obtained plate-like body or molded body are determined. The density can be varied. This makes it possible to control the moisture permeability of the plate or the molded body. For example, the gap between the plate-like body or the molded body is 1 to 10
By about 0 μm, usually about 5 to 50 μm,
It is also possible to produce a good plate-like body or molded body that has air permeability but does not allow rain to pass through.

Further, the palm fiber has a diameter of about 100 to 6
It is as thick as 00 μm, as long as about 5 to 30 cm, bent, and entangled with each other. It is preferable to use oil palm fiber as the palm fiber. This oil palm fiber is obtained by defibrating empty fruit clusters of oil palm. Oil palm fiber requires less labor for defibration and the like than other types of palm fiber, so that the energy required for production can be reduced and the cost can be reduced. For example, coconut fibers require a large amount of energy for a long period of time to be immersed in water for a long period of time to soften the coconut shell and then mechanically defibrated into a fibrous state. On the other hand, in the case of oil palm, since the empty fruit clusters which are originally fibrous and aggregated are defibrated, there is no need for immersion in water, and very little energy is required for defibration. In addition, oil palm fibers are less dust-producing than coco fiber and are preferred because handling thereof does not deteriorate the working environment.

The oil palm fibers are optionally washed before and after defibration to remove oil and odor. The oil palm fiber alone has a high rigidity and a cross-sectional diameter of 100 to 6
It is about 00 μm and its hair foot, that is, the length is about 5
It is about 30 cm, and by defibrating the fiber, a high degree of entanglement can be expected. Moreover, oil palm oil can be exploited from the oil palm fruit, but the empty fruit bunch remaining after harvesting this fruit has no specific use at present and is usually destined to be discarded, so it is low cost. It has the advantage of being available.

Further, this fiber mat may be mixed with natural plant fibers such as hemp fiber and bamboo fiber, if necessary. Here, examples of the natural plant fiber include hemp fiber that is fibrillated hemp, bamboo fiber that is fibrillated young bamboo, sugarcane fiber, hechima fiber, pineapple fiber, banana fiber, koulyan fiber, fiber obtained from Inawala, and wood fiber. There is no particular limitation as long as the fiber is obtained from a natural plant. These may be used alone or in combination of two or more. When vegetable fiber such as hemp fiber and bamboo fiber is mixed with the fiber mat, the diameter of the palm fiber is about 100. ~ 600
μm, the diameter of the hemp fiber is about 5-30 μm
m, bamboo fiber and the like have a small diameter of 10 to 200 μm, and it is considered that vegetable natural fibers such as hemp fiber and bamboo fiber are entangled at intersections of palm fibers and the like, and the bonding strength between palm fibers increases.

In order to form a fiber mat, the coconut fiber is entangled with a nonwoven fabric or a three-dimensional knitted structure by a needle punch or the like to increase the peel strength, and if necessary, the fiber is pressed by a press or hot press. Make the mat denser. The thickness of the fiber mat is usually 5 to 20 m.
m, it is said that it is easy to use. Of course, the fiber mat is not limited to this and may be set arbitrarily according to the use. Further, the basis weight of the fiber mat is, for example, 0.5 to 6 kg.
/ M ² . Also, a plurality of sheets may be used.

Examples of the amino resin of the present invention include urea resin (urea resin), melamine resin, urea-melamine copolymer resin, benzoguanamine resin, and acetoguanamine resin, phenol-melamine copolymer resin, and phenol-urea copolymer. Resins, phenol-melamine-urea copolymer resins. Among the above amino resins, urea resins, melamine resins, and urea-melamine copolymer resins are preferred from the viewpoints of curing time, price, and productivity.

The above-mentioned amino resin is provided as a solution or a powder using water or one or more mixed solvents of mainly water-miscible organic solvents such as methanol, ethanol, isopropanol and acetone. In addition, phenol, xylenol, cresol,
Methylenebisphenol, resorcinol, alkylresorcinol, catechol, alkylcatechol, hydroquinone, thiourea, pyrogallol, phloroglysin, alkylphenol, furan, cumarone, cyclohexane,
Compounds such as cashew oil, tannins, rosin, petroleum resin, toluene and xylene may be copolymerized as a copolymerizing agent or a modifying agent.

The amount of the amino resin to be used cannot be unequivocally determined because it varies depending on the physical properties required for the plate-like body 1. For example, the amount is 5 to 100% by weight, preferably 5 to 50% by weight, based on the weight of the fiber mat. More preferably, 10 to 30% by weight is exemplified. When the amount used is 5% by weight or less, the amount is insufficient as a fiber fixing agent, and a sufficient adhesive effect cannot be obtained. When the amount is 100% by weight or more, a further increase in strength can be expected. In addition, with respect to the moisture permeability, the gap formed by the fibers is closed by the resin, so that the moisture permeability decreases.

Further, the amino resins of the present invention include phenol resins, diallyl phthalate resins, alkylphenol-modified phenol resins, modified phenol resins such as rubber-modified phenol resins, furan resins, alkyd resins, unsaturated polyester resins, urethane resins, epoxy resins. , Modified silicone resin, and curable resin such as silicone resin and natural rubber and its derivatives, acrylic, styrene,
A vinyl-based or olefin-based thermoplastic resin, a copolymer resin thereof, a synthetic rubber such as SBR, a synthetic resin such as polyurethane, polyester, polyamide, or butyral resin, and an emulsion, latex, or aqueous solution thereof may be added.

The curable resin of the present invention may further contain a plasticizer, a filler, a reinforcing material, an anti-sagging agent, a coloring agent, if necessary.
An anti-aging agent, an adhesion promoter, a physical property modifier and the like can be added. Incidentally, konjac, flour, starch and the like may be added as an adhesion-imparting agent and a bulking agent. The method for attaching the amino resin is not particularly limited. Since large gaps are formed between the fibers in the fiber mat of palm fibers, when the amino resin is supplied by spraying or dipping, the amino resin adheres evenly to all the fibers through the gaps, thereby forming a plate-like body or The strength distribution of the compact becomes uniform.

As the curing agent of the present invention, those generally used as curing agents for amino resins can be used, and examples thereof include ammonium chloride, hydrochloric acid, ammonium sulfate, ammonium phosphate, and aniline hydrochloride. These may be used alone or in combination of at least two or more. An inhibitor may be added to these curing agents, and examples of the inhibitor include aqueous ammonia, hexamethylenetetramine, melamine, and urea. These inhibitors may be used alone or in combination of two or more. The amount of these hardeners is not particularly limited as long as the effect of the amino resin is sufficiently promoted. For example, 0.1 to 10% by weight, preferably 0.1 to 4% by weight, more preferably 0.5 to 2% by weight based on the weight of the amino resin. When the addition amount is 0.1% by weight or less,
When the effect of adding the curing agent is insufficient, and when the amount exceeds 10% by weight, the effect of increasing the amount is not observed even if it is added more.

The method for attaching the curing agent is not particularly limited. Since a large gap is formed between the fibers in the fiber mat of the palm fiber, when the curing agent is supplied by spraying or dipping, the curing agent uniformly adheres to all the fibers through the gap, thereby forming a plate-like body or The strength distribution of the compact becomes uniform. The hardening agent may be mixed with the amino resin in advance and then simultaneously attached thereto, or separately from the amino resin, before or after the amino resin is attached, or may be attached to the palm fiber.

The thickness of the plate 1 of the present invention is 3 to 25 mm.
Is preferable, and 9-20 mm is more preferable. When the thickness of the plate-like body is 3 mm or less, sufficient bending strength cannot be obtained,
When the thickness is 25 mm or more, it is considered that the wall thickness is increased in use applications, which is not practical in use. The density of the plate-like body 1 is preferably 0.2 to 1 g / cm ³ , and more preferably 0.3 to 0.
Preferably 7 g / cm ^3, a 0.35~0.6g / cm ^3. For example, when the thickness of the plate-like body 1 is 9 mm, the density is 0.2 g / cm ³ and the basis weight of the plate-like body 1 is 1.
8 kg / m ² , and 9 kg in density at 1 kg / m ³
/ M ² . When the density is 0.2 g / cm ³ or less, the strength of the plate-like body is not sufficient. When the density is 1 g / cm ³ or more, the moisture permeability is reduced, and the weight of the plate-like body or the molded body becomes too heavy and handling is poor. Become.

An embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a plate-like body 1 according to the first embodiment. This plate-like body 1 is formed by adhering an amino resin and a curing agent to a fiber mat 2 made of palm fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, if necessary, followed by compression molding. It is. First, the manufacturing method of the plate-like body 1 is as follows.
Palm fibers and, if necessary, hemp fibers are defibrated to obtain fibers having a unit cross-sectional diameter of about 5 to 600 μm and a length of about 5 to 30 cm. The defibrated coconut fibers include fibers having a larger cross-sectional diameter, thinner fibers, longer fibers and shorter fibers, but can be used as they are. At this time, since the natural length of the coconut fiber is about 5 to 30 cm, there is no particular need to process it. Next, the fibrous mat 2 is formed by mixing the fibrillated palm fiber with the fibrous natural fiber such as hemp fiber and bamboo fiber, if necessary. The mechanism used in this step includes, for example, a plurality of first, second,... Hoppers 12, 1 above a belt conveyor 11, as shown in FIG.
Are provided in series in the belt traveling direction, and each hopper 12
The spray guns 13 are respectively arranged in such a manner as to be directed to the vicinity of the outlet, and the heating and pressing roller 14 is provided downstream of the hopper 12 with the belt conveyor 11 facing the same. Each hopper 12 contains mixed fibers obtained by mixing coconut fiber, hemp fiber, bamboo fiber, and the like at an appropriate ratio, and spray guns 13, 13,.
An aqueous solution or aqueous dispersion of an amino resin and a curing agent is supplied under pressure. At the same time as the operation of the belt conveyor 11, the mixed fibers are dropped and supplied from each hopper 12 onto the belt conveyor 11, and the amino resin and the curing agent aqueous solution or the aqueous dispersion are supplied from each spray gun 13 toward the mixed fibers. Thereby, the lowermost first layer is formed on the belt conveyor 11 by the mixed fibers from the first hopper 12, and the second layer is formed thereon by the mixed fibers from the second hopper 12.
The fiber mat is formed by forming a layer, forming a fiber layer on the layer, and then press-molding the layer with a heat-press roller 14. Of course, when not mixing fibers, it is sufficient to supply only coconut fibers to all hoppers 12,
The hopper 12 and the spray gun 13 may be one.
Further, the spray gun 13 may be arranged in front of the hopper 12. Also, a plurality of first, second,.
By changing the characteristics (mixing ratio, fiber thickness, fiber length) of the fibers supplied to 2, 12,..., The characteristics of the fibers constituting each layer can be changed. In particular, in the case where thick palm fibers are arranged in the center of the fiber mat 2 and thin palm fibers are arranged on both surfaces, the contact density of the fibers on the surface side of the fiber mat 2 is increased, so that a plate-like body to be molded from this is obtained. 1 is good.

Next, the fiber mat 2 is subjected to heat compression molding. The mechanism used in this step is, for example, as shown in FIG. 3, while hemp cloths 4 and 4 are continuously supplied from above and below while pulling the fiber mat 2 forward, and spray guns 13 are respectively arranged at the merging portions. , And heat-pressing rollers 15, 15 are provided opposite to each other downstream thereof. An amino resin and an aqueous solution or aqueous dispersion of a curing agent are supplied under pressure to the spray guns 13, 13,.... At the same time as the operation of the belt conveyor 15, the amino resin and the hardener aqueous solution or the aqueous dispersion are jetted and supplied from each spray gun 13, and thereafter, the plate-like body 1 is formed by heating and pressing with the heat and pressure rollers 15, 15. Is continuously molded.

In addition to the continuous molding method, there is also a method of molding one sheet at a time. In this case, an amino resin and a curing agent are adhered to the fiber mat 2 to form a mold, and then subjected to thermocompression molding by a hot press or the like. Further, the plate-like body 1 may be formed one by one as follows. The curable resin is added to the vegetable natural fiber and stirred to adhere the curable resin.

Next, the above-mentioned fibers are filled in a mold (not shown) and formed into a plate-like material 1 with a predetermined thickness and a predetermined density by a hot press or the like. Further, in the above-described embodiment, the case where the fibrillated vegetable natural fibers are directly filled in the mold when forming the fiber mat 2 has been described. It is also possible to impregnate the resin, laminate this into multiple layers, and mold it. Thereby, a large physical strength can be obtained without impairing the moisture permeability.

Although the amino resin and the curing agent are attached to the fibers by spraying with a spray gun 13 or the like, they may be attached by dipping the fibers in the amino resin and the curing agent. In addition, the amino resin and the curing agent are mixed in advance and sprayed by the spray gun 13 or the like to adhere to the fibers, but these may be separately sprayed or dipped.

The amino resin and the curing agent are used as a sizing agent or a binder for the fiber mat 2 and also for imparting strength to the hemp cloth 4 itself and the hemp cloth 4 and the fiber mat 2.
And further acts as a binder for the entire plate or a component for imparting strength. Therefore, in the plate-like body 1 of the first embodiment, the fiber mat 2 is a palm fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, and the unevenness of the surface is larger than that of the artificial fiber. In addition to having a high entanglement strength between the fibers as compared to the artificial fibers, the bond strength with an amino resin due to a so-called anchor effect is excellent. Moreover, while the diameter of the palm fiber is about 100 to 600 μm, for example, the hemp fiber is as thin as about 5 to 30 μm, so that the vegetable natural fiber such as hemp fiber is entangled at the intersection of the palm fiber, The bond strength between palm fibers is increased. Further, bamboo fiber or the like has a flat shape and is rigid, so that mixing with coconut fiber has the meaning of improving strength and the like. Therefore, if the windproof layer is formed by the plate-like body 1, the heat-insulating layer can be stably held with high strength, and the plate-like body 1 can reinforce the structural portion around the windproof layer. .

The coconut fiber has a diameter of about 100 to 60.
Since it is as thick as 0 μm, when the fiber mat 2 is used, for example, 100 μm to 5 m
Since a gap having a size of about m is formed, the moisture permeability of the fiber mat 2 is extremely good. Accordingly, the plate-like body 1 of the present invention obtained from these materials can have various strengths and moisture permeability depending on the amount of the amino resin, the fiber mat 2, the compression ratio at the time of compression molding, and the like. Therefore, this plate-like body 1
Functions as an excellent windbreak layer.

In the above embodiment, the fiber mat 2 is prepared by mixing vegetable fiber such as hemp fiber and bamboo fiber with palm fiber, if necessary. However, the fiber mat 2 is formed only by palm fiber. May be. Next, the plate-like body according to the second embodiment of the present invention is provided on at least one surface and / or inside of a fiber mat made of palm fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, if necessary. Placing a knitted woven fabric made of vegetable natural fibers, a nonwoven fabric, or a sheet made of flakes, attaching an amino resin and a curing agent to them, and compressing and molding, it has both excellent moisture permeability and high strength, especially water absorption The rate of thickness change in the state is small.

The concept and characteristics of the coconut fiber, the configuration and the manufacturing method of the fiber mat, and the like are the same as those in the first embodiment. Vegetable natural fiber of the present invention, hemp fiber defibrated hemp, bamboo fiber defibrated young bamboo, sugarcane fiber, hemchima fiber, pineapple fiber, banana fiber, kouriang fiber,
Examples include fiber obtained from rice straw, wood fiber, cotton, and the like. There is no particular limitation as long as the fiber is obtained from a natural plant. These may be mixed alone or two or more types may be mixed at the same time.A knitted fabric is, for example, a cloth formed by knitting hemp yarn obtained by twisting hemp fibers obtained by defibrating hemp, both vertically and horizontally. And thus jute cloth, which is a cloth formed of jute. In addition, as for the nonwoven fabric, a hemp fiber obtained by defibrating hemp is made into a web in a dry manner, hardened with an adhesive such as a latex of natural rubber, dried and finished, and formed into a nonwoven fabric and a thin nonwoven fabric formed by a wet papermaking method. And paper formed by fibrillating wood fibers and wet papermaking. In addition, the sheet-like material includes a material obtained by knitting a thin strip-like thin piece cut out of a bamboo material or the like vertically and horizontally (actually, it is close to a weave). These knitted and woven fabrics, nonwoven fabrics and sheet materials have air permeability and are excellent in moisture permeability. The vegetable natural fiber used for the knitted fabric, the nonwoven fabric, and the sheet may be a mixture of a plurality of types of vegetable natural fibers. Further, two or more kinds of knitted fabrics, nonwoven fabrics and sheet materials may be used.

In the plate-like or molded article of the present invention, the fiber mat, knitted woven fabric, non-woven fabric and sheet-like material are all vegetable natural fibers and have larger irregularities on the surface than artificial fibers. Compared with this, it has the advantage that the entanglement strength between the fibers is large and the bonding strength with the curable resin due to the so-called anchor effect is excellent. The knitted fabric or sheet-like material is knitted or woven with hemp fibers or bamboo flakes having a high tensile strength and tensile elasticity, and therefore exhibits excellent tensile strength and tensile elasticity. The nonwoven fabric has a lower strength than a knitted fabric such as hemp or a sheet material such as bamboo, and is preferably a knitted fabric or a sheet material, but has a function as a holding material for a curable resin. If necessary, synthetic fibers such as nylon, polypropylene, polyethylene and polyester may be mixed with the natural fibers forming the nonwoven fabric.

Since the knitted fabric, nonwoven fabric or sheet is strongly bonded to the fiber mat via the curable resin, the strength of the plate or the molded body is increased. That is,
When the knitted woven fabric, nonwoven fabric or sheet is placed on the surface of the fiber mat, especially on both surfaces, a so-called sandwich effect is exerted, and the bending strength and flexural modulus of the plate or formed body are increased. On the other hand, when the knitted fabric, nonwoven fabric or sheet is placed inside the fiber mat, the tensile strength and tensile modulus, shear strength and shear modulus, and in-plane compressive strength and The inner compression modulus increases. This in-plane compressive strength means the strength when receiving a compressive force in a plane stress state. Further, since the knitted fabric or sheet-like material has a small dimensional change at the time of water absorption and moisture absorption, when placed on the surface or inside of the fiber mat, the dimensional change at the time of water absorption or moisture absorption of the plate-like or molded product becomes small, and In addition, a decrease in strength during moisture absorption is reduced.

The knitted fabric, nonwoven fabric or sheet-like material
The basis weight of 10 to 1500 g / m^TwoHas strength and moisture permeability, shape
It is preferable from the viewpoint of stability and the like. More preferably 100
~ 600g / m^Two, More preferably 150 to 350 g /
m^TwoIt is. The basis weight is 10 g / m ^TwoIn the following cases, the above songs
Reinforcement effects such as compression strength and compression strength are reduced. Also,
The basis weight is 1500 g / m^TwoWhen it is over, woven fabric, non-woven fabric,
The plate-like body and the molded body are dragged by the deformation of the sheet-like body,
Warpage and torsion after shape increase.

In the present invention, a knitted fabric using hemp fiber is particularly preferable. Here, the hemp includes those that take the skin fibers such as hemp (burlap), hemp, flax, mao, and ambassadors, and those that take the tissue fibers such as Manila, sisal, New Zealand and Mauricias. Hemp fibers refer to fibers obtained from these hemp. Since hemp (burlap) fiber is called jute, hemp fiber here includes jute.

Examples of hemp knitted and woven structures include plain weave,
It is preferable to select from twill weave, satin weave, nanako weave (including regular and irregular), and among them, plain weave and twill weave are particularly preferred. The knitting structure is selected from flat knitting, rubber knitting and the like.
The driving density is selected according to the combination of the weave structure and the yarn count.
If it is necessary to further improve the water resistance of the knitted fabric, nonwoven fabric or sheet-like material, silicon or the like may be applied to the surface of the knitted fabric or sheet-like material. Further, a flame retardant, a coloring agent, a preservative, a termiticide, a fungicide and the like may be applied as required.

The concept of the amino resin, the method of attaching the amino resin, and the preferred range of the thickness of the plate are the same as those in the first embodiment. Further, the manufacturing method of the plate-like body is described in the first embodiment except that a step of arranging hemp cloth on a fiber mat at an appropriate stage and attaching an amino resin and a curing agent thereto is included, for example. This is the same as the manufacturing method, and the points to be noted in the manufacturing method are the same as those in the first embodiment.

Accordingly, in the plate-like body 3 of the second embodiment, the fiber mat 2 is a palm fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, and the hemp cloth 4 is formed of hemp fiber. As a result, the irregularities on the surface are larger than those of artificial fibers and the like, so that the entanglement strength between the fibers is larger than that of the artificial fibers, and the bonding strength with the amino resin by the so-called anchor effect is excellent. Moreover, the diameter of palm fiber is about 100
For example, hemp fiber has a diameter of about 5 to 30 μm, which is thin, whereas vegetable natural fiber such as hemp fiber is entangled at intersections of palm fibers, thereby increasing the bonding strength between palm fibers. . Further, bamboo fiber or the like has a flat shape and is rigid, so that mixing with coconut fiber has the meaning of improving strength and the like. Therefore, if the windproof layer is formed by the plate-like body 3, the heat-insulating layer can be stably held with high strength, and the plate-like body 1 can reinforce the structural portion around the windproof layer. .

The palm fiber has a diameter of about 100 to 60.
Since it is as thick as 0 μm, when the fiber mat 2 is used, for example, 100 μm to 5 m
Since a gap having a size of about m is formed, the moisture permeability of the fiber mat 2 is extremely good. The hemp cloth 4 also has excellent breathability because the stitches have air permeability. Accordingly, the plate-like body 3 of the present invention obtained from these materials can have various strengths and moisture permeability depending on the amount of the amino resin, the fiber mat 2, the compression ratio at the time of compression molding, and the like. Therefore, the plate-like body 3 functions as an excellent windproof layer.

Since the hemp cloth 4 is made of hemp fibers or the like having a moderately high tensile strength and tensile modulus, the cloth itself exhibits excellent tensile strength and tensile modulus. Since the hemp cloth 4 is strongly bonded to the fiber mat 2 via the curable resin, the strength of the plate-like body 1 is increased. That is,
When hemp cloth 4 is arranged on both sides of fiber mat 2,
The so-called sandwich effect is exerted, and the bending strength and the bending elastic modulus of the plate-like body 1 are increased. In addition, hemp cloth 4
Is small since the dimensional change during water absorption and moisture absorption is small. In particular, it is preferable to dispose it on both surfaces of the fiber mat 2 because the dimensional change during water absorption and moisture absorption of the plate-like body or the molded body and the decrease in strength during water absorption and moisture absorption are small. Therefore, the plate-like body 1 functions as a structural surface material, and can reinforce the structural portion around the windbreak layer.

In the second embodiment shown in FIG. 3, the knitted woven fabric, nonwoven fabric or sheet-like material 4 is disposed on both surfaces of the fiber mat 2. One where only one surface of the fiber mat 2 is arranged, one where the knitted woven fabric, non-woven fabric or sheet-like material 4 is arranged inside the fiber mat 2, and one where the knitted woven fabric, non-woven fabric or sheet-like material 4 is placed on both surfaces of the fiber mat 2 or 1 Placed on the surface and inside,
Is included.

FIG. 4 shows a plate-like body 1 according to a third embodiment. The plate-like body 1 is composed of a fiber mat 2 and a knitted or woven fabric, a nonwoven fabric or a sheet disposed inside the fiber mat 2. It is formed in a plate shape having a predetermined thickness from the material 4 and the knitted fabric, nonwoven fabric or sheet material 4 arranged on both surfaces of the fiber mat 2. Further, when the knitted woven fabric, nonwoven fabric or sheet-like material 4 is arranged inside the fiber mat 2, the knitted woven fabric, nonwoven fabric or sheet-like material 4 is divided into a plurality of pieces, Coconut fibers and the like are alternately stacked and arranged in a multilayer shape. When the knitted or woven fabric, the nonwoven fabric, or the sheet-like material 4 is arranged inside the fiber mat 2, if the treatment with a needle punch or the like is performed in such an arrangement, the fiber mat 2 and the knitted fabric,
The fibers of the nonwoven fabric or the sheet-like material 4 are well entangled with each other, so that the peel strength of the plate-like body or the molded body is increased, and the bending strength and the flexural modulus are improved.

When the knitted fabric, nonwoven fabric or sheet-like material 4 is arranged inside the fiber mat 2, the tensile strength and the tensile modulus, the shear strength and the shear modulus of the plate 1, the in-plane compressive strength and Because the in-plane compression modulus increases,
The plate-like body 1 functions as a structural surface material, and can reinforce the structural portion around the windbreak layer. Furthermore, in the first embodiment, only the knitted or woven fabric 4 obtained by weaving yarn obtained from hemp fiber is used, but the knitted or woven fabric, the nonwoven fabric or the sheet is used in combination with the sheet 4 obtained by knitting a thin piece cut out of a bamboo material or the like. When a plurality of articles 4 are used, they may be used in an appropriate combination.

In the above embodiment, only a plate-like body having a rectangular shape in a front view and a constant thickness has been described. However, a molded body formed into a desired shape by using various types of molds during compression hardening molding may be used. In this case, the same operation and effect as those of the above plate-like body can be obtained.

[0048]

Next, examples of the present invention will be described together with comparative examples. <Example 1> Using a defibrated oil palm fiber, the fiber was entangled by needle punch to prepare a fiber mat. Then, a urea resin (U-755 manufactured by Mitsui Toatsu Co., Ltd.) hardener mixed solution adjusted to a urea resin concentration of 40% and ammonium chloride of 0.4% is sprayed on the oil palm mat having a basis weight of 3.6 kg / m ² by a spray method. Then, a urea resin having a solid content of 20% by weight based on the weight of the mat was attached. Next, the plate was hot-pressed at 165 ° C. for 10 minutes using a press machine to obtain a plate-like body having a thickness of 9.0 mm. The resulting plate is
The following evaluation items and methods were used for evaluation. Flexural strength measurement
JIS A 5905 Based on the measurement method of fiberboard. The moisture permeability is JIS
Z 0208 Measured according to the moisture permeability test method of the moisture-proof packaging material. The measurement of the rate of change in thickness in a water-absorbing state was performed by a measuring method of JIS A 5905 fiberboard. The evaluation results are shown in Table 1.

Example 2 In the same manner as in Example 1, a mat having a basis weight of 3.6 kg / m ² and a melamine resin concentration of 4 were used.
A melamine resin (U-814 manufactured by Mitsui Toatsu Co., Ltd.) adjusted to 0% and ammonium chloride 0.4% was adhered so as to have a solid content of 15% by weight with respect to the mat weight to form a plate-like body. A 9.2 mm thick plate was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1.

Comparative Example 1 In the same manner as in Example 1, a mat having a basis weight of 3.7 kg / m ² was used, and a urea resin having a resin concentration of 40% was used to reduce the solid content to 20% by weight based on the weight of the mat. A urea resin was adhered to form a plate-like body. A plate having a thickness of 8.8 mm was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1.

Comparative Example 2 In the same manner as in Example 1, a mat having a basis weight of 3.5 kg / m ² was used, and a melamine resin having a resin concentration of 40% was used.
A urea resin was adhered so as to be in a weight% to form a plate. A plate having a thickness of 9.0 mm was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1. <Comparative Example 3> A commercially available sheathing board Asadas D manufactured by Daiken Kogyo was also evaluated for physical properties in the same manner as in Example 1. The results are shown in Table 1. The thickness of the used sheathing board is 1
1.5 mm.

From Table 1, it can be seen from Examples 1 and 2 that the use of an amino resin and a curing agent exhibited excellent performance in both strength and moisture permeability, and that the rate of change in thickness during water absorption was particularly small. all right.

[0053]

[Table 1]

<Example 3> Using a defibrated oil palm fiber, the fiber was entangled with a needle punch to prepare a fiber mat. Then, a urea resin (U-75 manufactured by Mitsui Toatsu Co., Ltd.) was prepared by adjusting the oil palm mat having a basis weight of 3.0 kg / m ² to a urea resin concentration of 40% and ammonium chloride of 0.4%.
5) The mixed solution of the curing agent was sprayed by a spray method, and 10% by weight of urea resin was attached as a solid content of urea resin to the mat weight. Next, jute cloth (basis weight 320g /
m ² ) A mixture of a urea resin and a curing agent adjusted to a urea resin concentration of 20% and ammonium chloride of 0.2% is applied to two sheets by a spray method so that the urea resin solid content is 10% by weight based on the weight of the jute cloth. I let it. Subsequently, after jute cloth, oil palm fiber mat, and jute cloth were stacked in this order, they were heated and pressed by a press machine at 165 ° C. for 10 minutes to obtain a plate having a thickness of 9.0 mm. The obtained plate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 2.

<Example 4> In the same manner as in Example 3, a mat having a basis weight of 3.1 kg / m ² and a urea resin concentration of 40 were used.
%, And a urea resin (U-755 manufactured by Mitsui Toatsu Co., Ltd.) hardener mixed solution adjusted to 0.2% ammonium chloride was applied so that the urea resin solid content was 10% by weight based on the mat weight. Next, a urea resin concentration of 20% and an ammonium chloride 0.1% were adjusted to a urea resin solid content of 10% by weight to a jute cloth having a basis weight of 320 g / m ² , and a mixed solution of a curing agent was adhered. A plate was formed. A 9.2 mm thick plate was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 2.

<Comparative Example 4> In the same manner as in Example 3, a mat having a basis weight of 3.1 kg / m ² and a urea resin concentration of 40 were used.
% Of a urea resin (U-755 manufactured by Mitsui Toatsu Co., Ltd.) was applied to the mat so that the urea resin solid content was 10% by weight based on the mat weight. Next, basis weight 320g
/ M2 of jute cloth with urea resin solid content of 10
A urea resin adjusted to have a urea resin concentration of 20% and a mixed solution of a curing agent were adhered to each other to form a plate-like body. A plate having a thickness of 9.0 mm was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 2.

From Table 2, it can be seen from Examples 3 and 4 that the use of an amino resin and a curing agent provided excellent performance in both strength and moisture permeability, and particularly high wet strength.

[0058]

[Table 2]

[0059]

As described above, according to the plate-like body or the molded article of the present invention, a large gap formed between the thick palm fibers in the fiber mat and a breathable knitted woven fabric, nonwoven fabric, The sheet-like material provides excellent moisture permeability, and the knitted fabric or the sheet-like material is knitted or woven with hemp fibers or bamboo flakes having a moderately high tensile strength and tensile elastic modulus, and therefore is excellent in itself. The measured tensile strength and tensile modulus are shown below. In addition, vegetable fiber such as coconut fiber and resin are strongly bonded to each other, and the fiber mat is reinforced by a knitted fabric or sheet-like material having high tensile strength and tensile elastic modulus, so that high strength is obtained as a whole and water absorption is achieved. Also, the dimensional change and the decrease in strength during moisture absorption are small. Also, by adhering an amino resin and a curing agent and performing compression molding, the resin has both excellent moisture permeability and high strength, and particularly has a small rate of change in thickness in a water-absorbing state. Therefore, if the windbreak layer is formed from this plate-like body or molded body, it is easy to construct, and it is possible to smoothly transmit the indoor water vapor through the ventilation layer and stably hold the heat insulation layer. The structural part around the windbreak layer can be reinforced by the plate-like body or the molded body.

Further, a production method suitable for the plate-like body or the molded body of the present invention could be proposed.

[Brief description of the drawings]

FIG. 1 is a perspective view of a plate-like body according to a first embodiment.

FIG. 2 is an explanatory diagram showing a method for producing the fiber mat of the first embodiment.

FIG. 3 is a cross-sectional view illustrating an example of a sheet-like material according to a second embodiment.

FIG. 4 is a sectional view of a plate-like body according to a third embodiment.

[Explanation of symbols]

 Reference Signs List 1 plate-like body 2 fiber mat 3 plate-like body 4 hemp cloth (knitted fabric), non-woven fabric, sheet-like material

Claims (11)

[Claims] 1. A plate-like body or a molded product obtained by adhering an amino resin and a curing agent to a fiber mat composed of palm fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, if necessary, followed by compression molding. body. 2. A knitted woven fabric, non-woven fabric or flake made of vegetable natural fiber is provided on at least one surface and / or inside of a fiber mat made of palm fiber mixed with vegetable natural fiber such as hemp fiber and bamboo fiber as required. Place a sheet-like object
A plate-like body or a molded body obtained by adhering an amino resin and a curing agent thereto and subjecting them to compression molding. 3. The coconut fiber according to claim 1, wherein the coconut fiber is oil palm fiber.
3. The plate-like body or molded body according to 2. 4. The plate-like body or molded article according to claim 1, wherein the amino resin is a resin selected from at least one of urea resin, melamine resin, and urea-melamine copolymer resin. 5. A palm fiber mixed with a vegetable natural fiber such as a hemp fiber or a bamboo fiber according to need.
3. The method according to claim 1, wherein the coating is applied in an amount of 00% by weight.
3. The plate-like body or molded body according to 3 or 4. 6. The plate or molded article according to claim 1, wherein the curing agent is ammonium chloride. 7. The curing agent is used in an amount of 0.1 to 1 with respect to the amino resin.
4. The method according to claim 1, wherein 0% by weight is added.
The plate-like body or molded body according to 4, 5, or 6. 8. The molded article has a density of 0.35 to 0.6 g / c.
Claim 1, 2, 3, 4, characterized in that the m ^3,
The plate-like body or the molded body according to 5, 6, or 7. . 9. A knitted woven fabric, a nonwoven fabric or a sheet made of flakes made of vegetable natural fibers has a basis weight of 10 to 1500 g.
/ M ² , the plate-like body or the molded body according to claim ² , 3, 4, 5, 6, 7, or 8. 10. The plate or molded article according to claim 2, wherein the knitted fabric is a hemp cloth made of hemp fiber. 11. A fiber mat is formed by mixing planted natural fibers such as hemp fiber and bamboo fiber with the defibrated palm fiber, if necessary, and at least one surface and / or inside the fiber mat as required. , A knitted fabric made of vegetable natural fibers,
The plate according to any one of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 wherein a sheet-like material made of a nonwoven fabric or a flake is arranged, an amino resin and a curing agent are adhered to these, and compression-molded. A method for producing a shaped body or molded body.