JPH1015920A - Molded board wherein grain husk is used and manufacture of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molded board wherein grain husk and a foamable phenol resin are used and a method for manufacturing it. SOLUTION: This molded board comprises a foamable phenol resin 1, grain husk and mat-like fiber 3 and the foamable phenol resin 1 and the grain husk 2 sprayed on the mat-like fiber 3 after mixing or into a layer is heated at a temp. being at least the softening temp. and at most the foaming temp. of the foamable phenol resin 1 to obtain a prepreg. The prepreg alone or a plurality of the prepregs being laminated are heated and pressed to obtain an aimed molded board. As no glass fiber is used, there exists no possibility of making working environment worse during manufacturing process and used board is easily reused.

Description

DETAILED DESCRIPTION OF THE INVENTION

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded board used as a core material for an automobile interior material, a core material for a cabinet of furniture or home electric appliances, a core material for an interior material for a building, and a method of manufacturing the same.

2. Description of the Related Art Conventionally, wood fiber boards, polypropylene foams, cardboards and the like have been used as core materials for automobile interior materials. Further, glass fiber reinforced phenolic resin foams having better mechanical properties than these have been widely used. However, the glass fiber reinforced phenol resin foam has a problem that the working environment is deteriorated in the manufacturing process because glass fiber is used as the reinforcing material or the reinforcing material. In recent years, there has been increasing interest in reusing various materials from the viewpoint of protecting the global environment.
In Europe, in particular, some automakers have refrained from adopting materials for which recycling methods have not been established. In a core material for an automobile interior material using a glass fiber reinforced phenol resin foam, there is a problem that it is difficult to reuse glass fiber. On the other hand, the cereal hull, for example, corn hull, is obtained as a by-product when producing starch from corn grains, and a concentrated solution of soluble protein (corn steep liquor) obtained by a wet milling method and other components are added and dried. It was included in livestock feed as corn gluten feed. However, as the quality of livestock feed has been improved in recent years, the use of corn hulls for the same purpose has been stopped, and 50 to 55
There are situations where 10,000 tons of corn hulls remain unused.

SUMMARY OF THE INVENTION The present invention has been developed in view of the above-mentioned conventional circumstances, and an object of the present invention is to use cereal hulls which are unused resources without using glass fibers. Accordingly, it is an object of the present invention to provide a molded board which has sufficient characteristics, is inexpensive and lightweight, has good characteristics, and is easy to reuse, and a method for producing the same, without causing deterioration of the working environment in the production process.

DISCLOSURE OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and comprises combining a cereal hull, which is an unused resource such as a corn hull, with an expandable phenol resin to provide a mechanical strength of a molded board. Have been found to be improved, and the present invention has been completed. That is, after mixing the foamable phenolic resin 1 and the cereal hull 2 or dispersing each of them in layers on the same mat-like fiber 3, the temperature condition is higher than the softening point temperature of the foamable phenolic resin 1 and lower than the foaming temperature. The prepreg shown in FIG. 1 is obtained by heating and fusing. As shown in FIG. 2, a molded board is obtained by heating and pressurizing the prepreg, which is singly or plurally laminated, at a temperature not lower than the foaming / curing temperature. When laminating the prepreg, the resin-fused surface may be placed inside, and the foamed phenol resin-fused surface and the mat-like fiber 3 may be laminated.
May be alternately stacked. The molded board is lightweight and has sufficient mechanical properties, and is easier to dispose of when compared to glass fiber reinforced boards. FIG. 2 shows an example of a molded board obtained by stacking the prepreg with the foamable phenol resin-fused surface inside, heating and pressing, and the phenol resin foam containing the cereal hull 2 inside the mat-like fiber 3. Is formed. As the foamable phenol resin, a novolak-type phenol resin or a resol-type phenol resin obtained by imparting foamability can be used. As the mat-like fibers 3, natural fibers or synthetic fibers can be used. Considering the processing of used boards, the use of natural fibers is preferred. As the natural fiber, one or a mixture of two or more of pulp, hemp, cotton, wood fiber and palm fiber can be used to form a mat. As synthetic fibers,
Polyester fiber, polyamide fiber, acrylic fiber, polyacetal fiber, high-strength vinylon fiber, phenol fiber, carbon fiber, silicon carbide fiber, boron fiber, or a mixture of two or more types of alumina fiber to form a mat. Can be used. As the cereal hull 2, corn or wheat hulls (brass) can be used alone or in combination. The cereal hull 2 is usually supplied in flake form. In the present invention, it may be used in the form of flakes or may be pulverized and used in powder form. In order to uniformly mix the effervescent phenolic resin 1 and the cereal hull 2, the cereal hull 2 is preferably ground and used. Cereal hull 2
May be preliminarily mixed with the foamable phenolic resin 1 and pulverized and mixed at the same time as the foamable phenolic resin 1, or may be pulverized separately from the foamable phenolic resin 1. The particle size of the cereal hull 2 when pulverized is 10 to 1000 μm, preferably 100 to 500 μm. The mixing ratio of the foamable phenolic resin 1 and the cereal hull 2 is 1: 5 to 5: 1 by weight, preferably 1: 3 to 3: 1. If the ratio of the foamable phenolic resin 1 is higher than this, the contact between the cereal hulls 2 decreases, and the obtained molded product cannot have sufficient mechanical strength. Conversely, if this ratio is low,
The phenolic resin foam is not sufficiently filled in the gap between the cereal hulls 2 and the molded body becomes brittle. The thickness of the molded body is 1-20mm
Preferably 3 to 10 mm, density 0.1 to 1.0 g / c
m ^3, preferably 0.3 to 0.5 g / cm ³ .

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to embodiments, but the present invention is not limited to the following embodiments. The “part” in the embodiment
Are by weight unless otherwise specified. [Embodiment 1] 100 parts of novolak-type foamable phenol resin powder and 100 parts of corn hull are mixed by a mixer. The mixture is sprayed on a pulp mat so as to have a uniform thickness and heated in a heating furnace to fuse the resin mixture on the pulp mat to obtain a prepreg. Heat the two prepregs with the resin side inside and
Pressure molding was performed to obtain a molded board having a thickness of 5 mm. The basis weight of the pulp mat was 100 g / m ² , and the basis weight of the mixture of the phenol resin and the corn hull was 2300 g / m ² . Pulp mat basis weight 100 g / m ² in the same manner as the first embodiment [embodiment 2], to obtain a molded board having a basis weight 2300 g / m ² of phenol resin and corn hulls mixture. However, the mixing ratio was 130 parts of the corn husk with respect to 100 parts of the phenol resin. Embodiment 3 A molded board having a basis weight of pulp mat of 100 g / m ² and a basis weight of a mixture of phenol resin and corn hulls of 2300 g / m ² was obtained in the same manner as in Embodiment 1. However, the mixing ratio was 100 parts of the phenol resin and 77 parts of the corn skin. Pulp mat basis weight 100 g / m ² in the same manner as the first embodiment [Fourth Embodiment], to obtain a molded board having a basis weight 1100 g / m ² of phenol resin and corn hulls mixture. However, the mixing ratio was 50 parts of corn skin with respect to 100 parts of the phenol resin. Pulp mat basis weight 100 g / m ² in the same manner as the first embodiment [Embodiment 5], to obtain a molded board having a basis weight 3800 g / m ² of phenol resin and corn hulls mixture. However, the mixing ratio was 100 parts of phenol resin and 200 parts of corn skin. [Comparative Example 1] Similar to Embodiment 1, pulp mat weight per unit area 100 g / m ² , phenol resin weight per unit area 2000 g
/ M ² . [Comparative Example 2] A molded board having a basis weight of 1800 g / m ² of a mixture of phenolic resin and corn husk was obtained in the same manner as in Embodiment 1 by using a glass chop strand mat (manufactured by Asahi Fiber Glass Co., Ltd.) with a basis weight of 600 g / m ^2. Was. However, the mixing ratio was 100 parts of corn husk with respect to 100 parts of the phenol resin. Comparative Example 3 A glass chop strand mat (manufactured by Asahi Fiber Glass Co., Ltd.) has a basis weight of 600 g / m ² and a phenol resin basis weight of 1800 g in the same manner as in the first embodiment.
/ M ² . Table 1 shows the results of the bending strength tests of Embodiments 1 to 5, and Table 2 shows the results of the bending strength tests of Comparative Examples 1 to 3.

[Table 1]

[Table 2] As is clear from Tables 1 and 2, in the first embodiment, the bending strength is remarkably improved although the amount of the resin used is about half that of the comparative example 1. The bending strength of the molded board using pulp mat as a surface material and mixing gluten feed and resin was almost the same as that of a board formed using glass fiber as a surface material and not mixing gluten feed (Comparative Example 3). Since it has strength and does not use glass fiber, it is easy to handle.

As described above, according to the present invention, it is possible to provide a molded board that effectively utilizes unused resources such as corn hulls without using glass fibers. Further, according to the present invention, a molded board that can be easily disposed at the time of disposal can be manufactured at low cost without adversely affecting the working environment.

[Brief description of the drawings]

FIG. 1 is a perspective view of a sheet obtained by fusing a resin mixture on a mat-like fiber of the present embodiment.

FIG. 2 is a perspective view of a molding board according to the present embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Foamable phenolic resin 2 Grain hull 3 Matte fiber

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B27N 3/00 B27N 3/00 D B29C 67/14 GBB29K 61:04 105: 04 105: 08 511 : 10 B29L 9:00 31:10 31:44 31:58 (72) Inventor Takenari Nakayama 700, Shukudaidaicho, Takasaki City, Gunma Prefecture Gunei Chemical Industry Co., Ltd.

Claims (10)

[Claims] 1. A mixture obtained by mixing foamable phenolic resin and cereal hulls or dispersing them in layers in a uniform manner on a mat-like fiber, heating and fusing, and then heating and pressing. Molded board. 2. The molded board according to claim 1, wherein the foamable phenolic resin is a novolak-type phenolic resin or a resol-type phenolic resin having foamability. 3. The molded board according to claim 1, wherein the mat-like fibers are natural fibers or synthetic fibers. 4. The cereal hull is a corn hull and / or a corn hull.
4. The molded board according to claim 1, wherein the molded board is a wheat hull. 5. 5. A method of manufacturing a molded board by mixing foamable phenolic resin and cereal hulls or uniformly dispersing each of them in layers on a mat-like fiber, heat-sealing and heating and pressing. Characteristic method of manufacturing a molded board. 6. The method for producing a molded board according to claim 5, wherein the foamable phenol resin is a novolak type phenol resin or a resol type phenol resin provided with foamability. 7. The method for producing a molded board according to claim 5, wherein the mat-like fibers are natural fibers or synthetic fibers. 8. The cereal hull is a corn hull and / or a corn hull.
8. The method for producing a molded board according to claim 5, wherein the molded board is a wheat hull. 9. A molded board obtained by heating or pressurizing after singly or plurally laminating a prepreg obtained by fusing an expandable phenol resin and a cereal hull on a mat-like fiber. 10. A method for manufacturing a molded board, comprising: prepreg obtained by fusing an expandable phenol resin and a cereal hull on a mat-like fiber alone or a plurality of prepregs, and then heating and pressing to produce a molded board. Method.