JPH11151707A - Fiber mat, fiber board, and production of them - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber board having high strength, good moisture permeability, and uniform density by obtaining a coconut palm fiber mat with uniform METSUKE (weight). SOLUTION: Coconut palm fibers charged from a hopper 5 are spread planely on a conveyer 4, transported to an upper condenser 6, sucked by the condenser 6, and stuck on the surface of a belt conveyer consisting of a porous substrate, and compressed into a layer with uniform METSUKE (weight). The compressed coconut palm fibers is sent to a lower condenser 7, sucked by the condenser 7, sucked on the surface of a belt conveyer consisting of a porous substrate, and compressed additionally. Subsequently, the laminar compressed fibers are sent to a discharge conveyer 9 through a compression roll 8, intertwined by a needle punching machine 10 locked together, and compacted to obtain a coconut palm fiber mat of uniform METSUKE (weight).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an outer wall base material, a floor material, a floor base material, a tatami mat, a roof base material, a ceiling material, a house interior material and an interior base material, a heat insulating material for a building, a body edge material, a sound insulation. Fiber board similar to wood-based fiber board that can be used as material, sound absorbing material, cushioning material, shock absorbing material, concrete formwork material, loading pallet, vehicle interior material such as automobiles, interior base material, furniture material, etc. And a fiber mat as a raw material of the fiber board, and a method for producing the same, particularly a fiber mat having a uniform basis weight,
The present invention also relates to a fiberboard produced from this fiber mat, having excellent moisture permeability and strength, and having a uniform density, and a method for producing them.

[0002]

2. Description of the Related Art In general, a wooden house with an aeration method is provided with a fiber-based heat insulating layer such as glass wool in a wall.
By forming a ventilation layer between the outer wall and the heat insulating layer to prevent indoor water vapor to escape to the outside and prevent dew condensation, the indoor water vapor that has passed through the heat insulating layer diffuses from under the eaves to the outside through the ventilation layer I am trying to do it. In that case, usually, a windproof layer is provided between the heat insulating layer and the gas permeable layer in order to partition the heat insulating layer and the gas permeable layer and hold the heat insulating layer.
This windproof layer is required not only to have a function of holding the heat insulating layer, but also to be able to smoothly transmit the water vapor that has passed through the heat insulating layer to the ventilation layer, and therefore has excellent strength and moisture permeability. Is required.

[0003] Conventionally, for example, a nonwoven fabric made of polyethylene has been used as the windproof layer. However, since the strength is insufficient, when the heat insulating layer is made of glass wool or the like, the expansion force of the heat insulating layer is pressed. As a result, there is a disadvantage that the nonwoven fabric swells and deforms, 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 (refer to the standard specification for construction work, JASS 24 insulation work (edited by the Architectural Institute of Japan)). Therefore, a sizing board, which is a kind of soft fiberboard having a relatively low density and breathability among wood fiberboards, is applied to the outside of the heat insulating layer, and the ends thereof are pillars, studs, beams, girders, or braces. By fixing to a structural material such as (reinforcing material such as a rim or a braid), a windproof layer having a certain strength is formed.

[0004]

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

Japanese Patent Application Laid-Open No. 8-336816 discloses that
As a windproof layer, a fiberboard having both strength and moisture permeability is disclosed, in which a curable resin is attached to a fiber mat made of coconut fibers, and this is heat-compressed. However, since the coconut fiber has a long length of 5 to 30 cm, it has been difficult to continuously produce a mat made of coconut fiber having a uniform basis weight. Therefore, the density of the fiberboard obtained from the fiber mat made of the coconut fiber is not always uniform.

[0006] The present invention is intended to solve the above-mentioned problems, and an object of the present invention is to provide a fiber mat made of coconut fiber having a uniform basis weight, and a high strength and moisture permeability produced from the fiber mat. An object of the present invention is to provide a fiber board which is good and has a uniform density, and a method for producing the fiber mat and the fiber board as described above.

[0007]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies in order to solve these problems. As a result, the coconut fibers are spread two-dimensionally, compressed by suction, and then entangled with a needle punch. The present inventors have found that a fiber mat having a uniform basis weight can be obtained, and have completed the present invention.

That is, the present invention is as follows. [1] A method for producing a fiber mat comprising the following steps (a) to (c). (A) A step of spreading palm fibers two-dimensionally. (B) a step of sucking the coconut fiber spread in a plane from the back side of the porous substrate to adsorb it on the surface of the substrate and compressing it. (C) a step of intertwining the coconut fibers that have been spread and compressed in a plane with a needle punch. [2] The method for producing a fiber mat according to [1], wherein the coconut fiber is a fiber defibrated from oil palm. [3] A curable resin is adhered to the fiber mat obtained by the production method according to the above [1] or [2] and, if necessary, dried, and then one or more of the fiber mats are stacked and compression-molded. Manufacturing method of fiberboard. [4] A curable resin is adhered to the fiber mat obtained by the production method according to the above [1] or [2] and, if necessary, dried, and then one or more of the fiber mats and the curable resin. Of a sheet-like material such as a knitted fabric or a nonwoven fabric to which
A method for producing a fiberboard, which comprises laminating a plurality of sheets or a plurality of sheets and compression molding. [5] It is manufactured by the method according to the above [1] or [2], has an average basis weight of 1.2 to 2.5 kg / m ² , and has a standard deviation of 0.03 to 0.15 kg in standard deviation. / M
Fiber mat that is ² . [6] A fiberboard produced by the method according to [3] or [4] and having a flexural strength of 3 to 50 N / mm ² . [7] The moisture permeability coefficient is 0.1 to 10 μg / (m ² · s · P
The fiberboard according to the above (6), which is a).

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. FIG. 1 shows a perspective view of a fiber mat 1 according to the present invention. The fiber mat 1 is formed by entangled coconut fibers in a three-dimensional knitted structure. FIG. 2 shows a fiberboard 2 according to the present invention.
FIG. The fiberboard 2 is formed by adhering a curable resin to a fiber mat 1 mainly composed of coconut fibers and compression-molding the fiber mat.

The coconut fibers used in the present invention include coconut,
Fibers such as fibrous bark, petiole base fiber, mesocarp fiber, etc. collected from palm plants such as oil palm, sago palm, date palm, saw palmetto, nippa palm, sugar palm, pea palm, palm, syrup, black clog, etc. Fiber obtained by defibrating empty fruit clusters. Further, a mixture of two or more kinds of coconut fibers is also included.

In addition to the above-mentioned coconut fibers, other fibers may be blended. For example, vegetable natural fibers such as hemp fibers and bamboo fibers can be used as a mixture with coconut fibers. In this case, for example, hemp fiber has a diameter of 5 to 30 μm and bamboo fiber has a diameter of 10 to 100 μm, while the diameter of the palm fiber is about 100 to 600 μm.
Since it is as thin as ~ 200 [mu] m, vegetable natural fibers such as hemp fiber and bamboo fiber are entangled at the intersections of the palm fibers, and the bonding strength between the palm fibers increases. These fibers are preferably used in an amount of 5 to 30 parts by weight based on 100 parts by weight of the coconut fiber.

It is preferable to use oil palm palm fiber as the palm fiber. The palm fiber of the palm is obtained by defibrating the empty fruit cluster of the palm. Oil palm palm fibers require less labor for defibration and the like than other types of palm fibers, so that the energy required for production can be reduced and the cost can be reduced. For example, coconut palms require a large amount of energy for a long period of time to be immersed in water for a long period of time in order to soften the coconut shells, and then mechanically defibrated into fibrous form. On the other hand, in the case of oil palm, since empty fruit clusters which are originally fibrous and aggregated are fibrillated, there is no need for immersion in water, and the energy required for fibrillation is extremely small. Further, the palm fiber of oil palm is less dust-producing than the palm fiber of coconut palm, and it is preferable because the working environment is not deteriorated in handling. Furthermore, oil palm oil is exploited from oil palm fruits, but the empty fruit clusters left after harvesting these fruits have no specific use at present and are usually destined to be discarded, so they can be obtained at low cost.

[0013] Among palm fibers, the palm fiber of oil palm is as thick as about 100 to 600 µm, and if it is used as a fiber mat 1, depending on the fiber packing density, for example, 100 µm A gap having a size of about 5 to about 5 mm, preferably about 200 μm to about 3 mm is formed. Therefore, the moisture permeability of the fiber mat 1 obtained from the palm fiber of oil palm is extremely good.

Further, the palm fiber of oil palm has a high rigidity of a simple substance, a large diameter as described above, a long bend of about 5 to 30 cm, and a large entanglement of the fibers. The fiberboard 2 manufactured from the fiber mat 1 obtained from the palm fiber of oil palm has excellent holding power when nailed.

The fiber mat 1 containing such palm fibers as a main component contains a hardened curable resin to form a fiber board 2. The cured curable resin serves as an adhesive between the palm fibers in the fiber mat 1 and a binder for the fiber mat 1. With such a configuration, the strength of the fiberboard 2 becomes good. Such a fiber board 2 is generally obtained by adhering a curable resin to the fiber mat 1 and curing it. In most cases, the curable resin is used in the form of an aqueous solution or an aqueous dispersion. .

Examples of the curable resin used in the present invention include thermosetting resins and reaction-curable resins (room-temperature-curable resins). First, examples of the thermosetting resin include a phenol resin, an amino resin, and a diallyl phthalate resin (DAP resin). Novolak resin (acid catalyst, excess phenol), resol resin (basic catalyst, excess formaldehyde), phenol-
Melamine copolymer resin, phenol-urea copolymer resin,
There are modified phenolic resins such as phenol-melamine-urea copolymerized resin, alkylphenol modified phenolic resin, rubber modified phenolic resin, and amino resins include urea resin (urea resin), melamine resin, urea-melamine copolymerized resin, benzoguanamine resin, And acetoguanamine resins. Next, examples of the reaction curable resin (room temperature curable resin) include a furan resin, an alkyd resin, an unsaturated polyester resin, a urethane resin, an epoxy resin, a modified (modified) silicone resin, and a silicone resin. Among these curable resins, thermosetting resins are preferable from the viewpoint of curing time and productivity, and among them, phenol resins and amino resins are more preferable.

As the collecting agent or binder of the fiber mat 1, the above-mentioned curable resin is used for dimensional accuracy, durability, and the like.
It is preferable in terms of strength and the like. However, although the physical properties are slightly inferior, it is also possible to partially use thermoplastic resins such as acrylic resins and styrene resins having a binder effect (particularly aqueous dispersions) and natural rubber latex or synthetic rubber latex such as SBR. The curable resin of the present invention is a concept including these.

In the fiber board 2 of the present invention, the curable resin serves as an adhesive between the fibers in the fiber mat 1 and a binder for the fiber mat 1 and a binder for a sheet-like material such as a knitted or woven fabric. , And acts as an adhesive between the sheet material such as a knitted fabric or a nonwoven fabric and the fiber mat 1, and further as a binder for the entire fiber board 2.

The curable resin used in the present invention includes:
If necessary, a plasticizer, a filler, a reinforcing material, an anti-sagging agent, a coloring agent, an antioxidant, an adhesion promoter, a curing catalyst, a physical property modifier, and the like may be added. Incidentally, konjac, flour, starch and the like can be added as an adhesion-imparting agent.

There is no particular limitation on the method of adhering the above-mentioned curable resin to a sheet material such as a fiber mat or a knitted or woven fabric to be laminated thereon. Since a large gap is formed between the fibers in the fiber mat of the palm fiber, when the resin is supplied by spraying or dipping, the resin uniformly adheres to all the fibers through the gap, and the strength distribution of the fiberboard is narrow. Become.

The fiber mat 1 of the present invention is manufactured, for example, by the following method. First, the palm fiber is spread flat. Next, in order to make the coconut fibers spread in a plane into a layer having a uniform basis weight, the coconut fibers are sucked from above, adsorbed on the surface of a first porous substrate, for example, a mesh substrate, and compressed. The amount of fibers adsorbed and compressed on the surface of the porous substrate is adjusted by adjusting the suction force at this time. Further, the first
After the coconut fibers adsorbed and compressed on the surface of the porous substrate are moved in the horizontal direction, they are dropped on a mesh-like substrate (second porous substrate) provided thereunder. Then, suction is performed from below the second porous substrate, and coconut fibers are adsorbed on the surface of the porous substrate and compressed again. The fibers are stacked in layers by this suction, so that the palm fibers can be prevented from inverting. When the palm fiber is inverted, a gap is opened in the horizontal direction of the fiber, which is not preferable because it causes uneven weight. Next, as described above, the coconut fibers adsorbed on the surface of the porous substrate and compressed on the surface of the porous substrate are entangled and entangled by a needle punch. In addition, as the porous substrate, in addition to the mesh-like substrate described above, a substrate having air permeability such as a knitted or woven substrate made of synthetic fibers, plant fibers, and mineral fibers can be used. Alternatively, a mesh-shaped or slit-shaped substrate made of metal can be used.

In the production of the fiber mat of the present invention, for example,
The device shown in FIG. 3 can be used. This apparatus is provided with a hopper 5 above the upstream side of the supply conveyor 4, a suction type upper condenser 6 above the downstream side of the supply conveyor 4, and a suction type lower condenser 7 below the downstream side. And a compression roll 8 opposed thereto, a discharge conveyor 9 provided further downstream of the compression roll 8, and a needle punch device 10 provided further downstream of the discharge conveyor 9. The specific structure of the upper condenser 6 and the lower condenser 7 is composed of a belt conveyor made of a porous substrate and an air suction device on the back surface thereof.

The production of the fiber mat 1 is as follows.
The coconut fibers fed from above are spread on a supply conveyor 4 in a planar manner and conveyed to an upper condenser 6. Next, the supplied coconut fiber is sucked by the upper condenser 6 and adsorbed on the surface of the belt conveyor made of the porous substrate, thereby compressing the cocoon fiber into a layer having a uniform basis weight. The compressed palm fiber is further sent to a lower condenser 7, and is further compressed by being sucked by the lower condenser 7 and adsorbed on the surface of a belt conveyor made of the porous substrate. Subsequently, the coconut fiber is sent to the discharge conveyor 9 via the compression roll 8 and is entangled by the needle punch device 10 by the needle punch device 10 to make it dense.

The thickness of the fiber mat 1 is usually about 5 mm to about 20 mm when performing heat compression molding, but it is easy to use. However, the thickness is not limited to this, and may be arbitrarily set according to the application. It is sufficient that a plurality of sheets are used.

The basis weight of the fiber mat 1 depends on the thickness and density of the fiber board manufactured using the same.
5 kg / m < ² > is preferable, More preferably, it is 1.4-2.
2 kg / m ² , particularly preferably 1.6 to 2.0 kg / m
² If the basis weight of the fiber mat 1 is less than 1.2 kg, the shape retention of the fiber mat 1 becomes insufficient, which is not preferable.
The fiber mat 1 having a basis weight of more than 2.5 kg / m ²
The curable resin is added to the fiber mat 1 during the production of the fiber board 2 in the post-process.
It is not preferable because it becomes difficult to adhere to the inside of the substrate. From the thickness and density of the fiberboard 2 to be manufactured, the basis weight is 2.5
When a fiber mat 1 exceeding kg / m ² is required, a plurality of fiber mats 1 may be used.

The basis weight distribution of the fiber mat 1 is, for example, standard
0.03-0.15kg / m in deviation ^TwoPreferably
And more preferably 0.03 to 0.1 kg / m^TwoIn
You.

Next, in the production of the fiberboard 2 of the present invention, for example, an apparatus shown in FIG. 4 can be used. This device comprises a spray gun 12 above and below a conveyor 11,
12 is installed, a drying device 13 is installed downstream of the spray guns 12, 12, and a cutting device 4 is installed downstream of the drying device 13. To manufacture the fiberboard 2, the curable resin is supplied under pressure to the spray gun 12, the fiber mat 1 is sent from the upstream side of the conveyor 11, and the spray gun 1 is
A curable resin is sprayed and supplied from both 2 and 12 to both surfaces of the fiber mat 1. Next, if necessary, after drying at 60 ° C. to 120 ° C. by the drying device 13, the material is cut to a required length by the cutting device 14. After one or a plurality of cut fiber mats 1 are stacked, the fiber mat 2 is repeatedly formed in a batch manner by a multi-stage hot press or the like. After the fiber mat 1 is cut, instead of being formed by a multi-stage hot press, the fiber mat 1 is compression-formed by a belt press, a heat compression roller or the like, and the fiber board 2 is continuously formed. You may cut it.

The thickness of the fiberboard 2 of the present invention is appropriately selected according to the strength and moisture permeability required of the fiberboard 2, but is preferably 3 mm to 25 mm, more preferably 9 mm to 20 mm.
It is. When the thickness is less than 3 mm, the strength may be insufficient. On the other hand, when the thickness is more than 25 mm, the heat compression molding becomes difficult, which is not preferable.

The density of the fiberboard 2 is appropriately selected according to the strength and moisture permeability required for the fiberboard 2, but is preferably 0.2 to 1.5 g / cm ³ , more preferably 0.1 to 1.5 g / cm ³ . 3 ~
1.0 g / cm ³ , particularly preferably 0.35 to 0.7
g / cm ³ . The density of the fiberboard 1 is 0.2 g / cm ³
If it is less than 3, for example, the bending strength becomes less than 3 N / mm ^2, and the quality as a sealing board in a JIS-A-5905 fiberboard is not satisfied, and conversely, 1.5 g / cm 2
If it exceeds ³ , the air permeability is insufficient, and the possibility of compressive failure of the fiberboard 2 due to an increase in the compressive force at the time of molding is increased.
In addition, the fiberboard 2 becomes too heavy, and the handling property such as carrying is deteriorated, which is not preferable.

The basis weight of the fiberboard 2 is set according to the thickness and density. For example, when the thickness of the fiberboard 2 is 9 mm, the density is 0.3 g / cm ³ and the basis weight is 2.7 kg / m ^2. When the density is 0.6 g / cm ³ , the basis weight is 5.4 kg / m.
It becomes ² .

The fiber board 2 has excellent strength.
Its bending strength is 3-50N / mm ^Two, Preferably 10
~ 40 N / mm^TwoAnd more preferably 15 to 30 N / m.
m^TwoIt has the performance of. In the present invention,
The bending strength is defined by the measurement method of JIS-A-5905.
It is measured according to.

Further, the fiberboard 2 of the present invention has a strength and a transparency.
It also has moisture permeability, and its moisture permeability coefficient is
0.1 to 10 μg / (m^Two・ S ・ Pa), especially preferred
Or 0.2 to 8 μg / (m^Two・ S ・ Pa), more preferred
Or 0.5-5 μg / (m ^Two・ S ・ Pa)
It has. In the present invention, the moisture permeability coefficient and
Is measured according to the measuring method of JIS-Z-0208.
Things.

In the present invention, in addition to the above-described production method in which palm fibers are spread two-dimensionally, compressed by suction and adsorption on the surface of a porous substrate, and then entangled with a needle punch, the coconut fibers adhere to the fiber mat. The amount of the curable resin to be used, the thickness of the fibers used in the fiber mat, the compression ratio at the time of hot compression molding, and the like are selected, and the density of the obtained fiberboard 2 is selected.
In other words, by controlling the size of the gap between the fibers, a fiber board having both strength and moisture permeability can be obtained. Specifically, the thickness of the coconut fiber as the main component is about 100 to 600 μm, and the curable resin to be used is 5 to 100 parts by weight with respect to 100 parts by weight of the fiber constituting the fiber mat.
By controlling the density of the fibers to about 0.2 to 1.5 g / cm ³ by setting the compression ratio at the time of thermocompression molding to 1/10 to 1/2 by weight, the gap of the fiberboard 2 is preferably 1
About 100 μm, more preferably about 5 to 50 μm, having a bending strength and a moisture permeability coefficient in the above ranges, having a breathability but not passing rain, and a fiber board 2 having excellent strength. Can be manufactured. Therefore, according to the fiberboard 2, an optimal windbreak layer can be formed according to the construction situation.

In the present invention, in order to further impart strength to the fiberboard 2, a curable resin is adhered to a sheet-like material such as a knitted fabric or a nonwoven fabric, and this is combined with the fiber mat 1 to which the curable resin is adhered. They may be laminated and heat-compressed.

Further, at the time of preparing the fiber mat 1, before needle punching, a sheet-like material such as a knitted or woven fabric is arranged above, below, or above and below the palm fiber, and is processed by needle punching or the like. Then, the fiber mat 1 and a sheet material such as a knitted fabric or a nonwoven fabric may be laminated.

The sheet-like material such as a knitted or nonwoven fabric used in the present invention includes natural fibers such as plant fibers, synthetic fibers, and the like.
Alternatively, a fiber made of a mixed fiber of a synthetic fiber and a natural fiber can be used. Natural fibers include cotton and hemp,
Examples include silk, bamboo, sugarcane fiber, loofah fiber, pineapple fiber, banana fiber, koulyang fiber, fiber obtained from rice straw, wood fiber, animal hair, and the like. Examples of the synthetic fiber include polyester fiber, aliphatic or aromatic polyamide fiber, aramid fiber, acrylic fiber, polyethylene fiber, polyolefin fiber such as polypropylene fiber, vinylidene fiber, polyvinyl chloride fiber, polyurethane fiber, vinylon, rayon, cupra. , Acetate and the like. Knitted or nonwoven fabrics made of inorganic fibers such as glass fibers, carbon fibers, and asbestos fibers can also be used.

These natural fibers, synthetic fibers, and, if necessary, synthetic fibers containing natural fibers may be used alone or in combination of two or more.

The basis weight of the sheet material such as a knitted fabric or a nonwoven fabric is preferably from 10 to 1500 g / m ² from the viewpoints of strength, moisture permeability, moldability and the like. More preferably, 10-600
g / m ^2, more preferably from 10~350g / m ^2.

As a preferred specific example of the knitted fabric as the above-mentioned sheet-like material, as shown in FIG. 5, a cloth 3 in which hemp yarns obtained by twisting hemp fibers are knitted vertically and horizontally is exemplified. here,
Hemp can be made from jute, flax, kenaf, and ambarisa, etc., as well as manila, sisal,
Tissue fibers such as New Zealand Asa and Mauricias Asa are included. Hemp fibers are fibers obtained by defibrating these hemp. Knitted fabrics include jute cloth, which is a cloth formed of jute.

Since the jute cloth 3 is made of knitted hemp fiber or the like having a high tensile strength and a high tensile modulus, the jute cloth 3 itself exhibits excellent tensile strength and a high tensile modulus. Examples of the weave structure of the jute cloth 3 are preferably selected from plain weave, twill weave, satin weave, nanaco 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. As an example of the yarn used here, jute count 7.
It is preferable to select from 5 to 40. Also, the basis weight is 100-1
It is preferably about 200 g / m ^{2, and} more preferably 100 to 1000
g / m ² , most preferably 100-600 g
/ M ² . When the basis weight is less than 100 g / m ² , for example, the dimensional change in the length direction at the time of water absorption exceeds 0.5%, and JIS
-The quality of the sheathing board in the fiberboard of A-5905 is no longer satisfied, and even if it exceeds 1200 g / m ² , the cost is high in spite of the fact that an increase in dimensional stability, an increase in reinforcing effect, etc. cannot be obtained. Is not preferred.

On the other hand, in the case of the nonwoven fabric, although the strength is inferior to that of the above-mentioned knitted fabric such as hemp, since the curable resin can be retained more than the knitted fabric, it can be applied to the fiberboard 2 after hot compression molding. Strength can be imparted. The fibers constituting the nonwoven fabric are not particularly limited, but natural fibers are preferable in consideration of the bonding force with the fiber mat 1, and synthetic fibers such as nylon, polypropylene, polyethylene, and polyester may be mixed as necessary. Also, for non-woven fabrics made of natural,
A web made from hemp fiber in a dry process, hardened with an adhesive such as a latex of natural rubber, dried and finished to form a nonwoven fabric, a thin nonwoven fabric formed by a wet papermaking method, and further, a wood fiber is defibrated, and a wet papermaking method is used. The paper to be formed is also included.

Among the non-woven fabrics, non-woven fabrics made of heat-meltable fibers that are hot-melted at the heating temperature during heat compression molding and can adhere to the coconut fiber mat can be suitably used from the viewpoint of adhesiveness and moldability. In this regard, a nonwoven fabric made of polypropylene, polyethylene, or polyester is most preferable.
There is no limitation on the fiber length, manufacturing method, and the like in this nonwoven fabric. That is, it may be a single fiber or a long fiber. As the production method, any of nonwoven fabrics produced by a general method such as a wet method, a dry method, a spun bond method, a flash spinning method, a melt blow method, and a spun lace method can be used.

These sheet materials such as knitted fabrics and nonwoven fabrics have air permeability and are excellent in moisture permeability. Further, in a single fiber board, two or more kinds of sheet materials such as a knitted fabric and a nonwoven fabric may be used in combination.

The amount of the sheet-like material to be laminated on the fiber mat 1 can be selected by a combination of the basis weight and the number of laminations depending on physical properties such as dimensional stability and strength required according to the use of the fiber board 2. , 5 to 5 parts per 100 parts by weight of coconut fiber
0 parts by weight is preferable, and 5 to 30 parts by weight is more preferable.
Most preferably, it is 10 to 25 parts by weight. If the amount of the sheet material is less than 5 parts by weight, for example, the dimensional change in the longitudinal direction at the time of water absorption exceeds 0.5%, and if it exceeds 50 parts by weight, the cost increases, which is not preferable.

In a fiber board 2 in which a sheet material such as a knitted fabric or a nonwoven fabric is arranged on the surface of the fiber mat 1, particularly on both surfaces, a so-called sandwich structure (the upper and lower parts of the body structure are made of a material having higher strength or rigidity than the body structure). Structure to strengthen)
The flexural strength and flexural modulus of the fiberboard 2 increase. on the other hand,
When a sheet-like material such as a knitted fabric or a nonwoven fabric is arranged inside the fiber mat 1, the tensile strength and the tensile modulus, the shear strength and the shear modulus of the fiberboard 2, and the in-plane compressive strength (in a plane stress state). The strength when receiving a compressive force) and the in-plane compressive modulus (the elastic modulus when receiving a compressive force in a plane stress state) increase.

Further, when the sheet-like material is formed of hemp fibers such as hemp cloth, the dimensional change during water absorption and moisture absorption is small. This is preferable because the dimensional change and the decrease in strength are small.

As described above, a sheet material such as a knitted or woven fabric is laminated on the surface of the fiber mat 1 or the fiber mat 1
By arranging a sheet-like material such as a knitted fabric or a non-woven fabric inside the fiberboard, the strength of the fiberboard 2 can be further improved. Further, by laminating a sheet material such as a knitted fabric or a non-woven fabric on at least one surface of the fiber mat 1, the surface property of the fiber board 2 can be changed, so that finishing is not required or the finishing material can be further applied to the surface. Or the like, to improve the retention of the finishing material when affixed to the surface. Further, if a sheet-like material such as a knitted fabric or a nonwoven fabric is made of a material having a high moisture permeability such as hemp fiber, a high moisture permeability can be obtained as a whole of the fiber board 2 without impairing the excellent moisture permeability of the fiber mat 1. be able to. Therefore, if the windproof layer is formed using such a fiberboard 2, the water vapor can be smoothly transmitted to the ventilation layer due to the high moisture permeability, and the heat insulation layer can be stably held due to the higher strength. The structural portion around the windbreak layer can be reinforced by the fiberboard 2.

When the sheet material such as the fiber mat 1, knitted fabric or nonwoven fabric is a vegetable natural fiber,
Since the unevenness of the surface is greater than that of artificial fibers, the entanglement strength between the fibers is higher than that of artificial fibers, and the so-called anchor effect (the adhesive penetrates into the voids on the surface of the material and solidifies to form a nail or wedge) By acting on
There is an advantage that the bonding between the fibers is improved by curing the curable resin.

Further, when it is necessary to further improve the water resistance of a sheet-like material such as a knitted or woven fabric, a water repellent such as wax or silicone is applied to the surface of the sheet-like material such as a knitted or woven fabric. You may make it. Further, a flame retardant, a coloring agent, a bactericide, a preservative, an ant-proofing agent and the like may be applied as necessary.

Further, in the above embodiment, only the fiber board 2 having a substantially constant thickness has been described. However, it may be formed into a desired shape by using various types of molds at the time of hot compression molding. In that case, only the final shape is different, and the description items regarding the fiberboard of the above embodiment can be applied as they are, and the same operation and effect can be obtained.

The use of the fiberboard of the present invention is not limited to the windproof layer formed in the wall, but is excellent in strength, moisture permeability, and productivity.
Flooring materials, tatami materials, roofing materials, ceiling materials, house interior materials and interior materials, architectural heat insulating materials, rim materials, sound insulation materials, sound absorbing materials,
It can also be used as a cushioning material, a shock absorbing material, a concrete form material, a loading pallet, a vehicle interior material such as an automobile, an interior base material, a furniture material, and the like.

[0052]

EXAMPLES Next, examples of the present invention will be described together with comparative examples, but the present invention is not limited to these examples.

[Measurement Method] Average weight of fiber mat and standard deviation of weight The fiber mat of 1m x 4m is cut into 25cm square, the weight of the cut fiber mat is measured, the weight is calculated from the weight and dimensions, and the average weight and standard deviation are obtained. . 2. Average density of fiberboard and standard deviation of density After cutting 1m x 2m fiberboard into 25cm square, measure the weight and dimensions (thickness, length, width) of the cut fiberboard,
The density is calculated from the weight and the size, and the average density and the standard deviation are obtained. 3. Flexural strength of fiberboard Measured according to the measuring method of JIS-A-5905. 4. Moisture permeability Coefficient is measured according to the moisture permeability test method of the moisture-proof packaging material of JIS-Z-0208.

Example 1 Oil palm fiber was spread on a 2.2 m wide supply conveyor 4 in a plane as shown in FIG. 3 and conveyed to an upper condenser 6, where the oil palm fiber was supplied. Was sucked by the upper condenser 6, adsorbed on the surface thereof and compressed, then sent to the lower condenser 7, sucked by the lower concentrator 7, adsorbed on the surface, and further compressed. Subsequently, the flatly compressed oil palm fiber was entangled with the needle punch device 10 to obtain a fiber mat having a width of 2.2 m and a width of 4 m. Cut off both sides of the obtained fiber mat by 10 cm and cut at the center in the width direction to obtain 1 m × 4 m
To obtain two fiber mats. As a result of examining the average basis weight and standard deviation of one obtained fiber mat, the average basis weight was 1.85 kg / m ² and the standard deviation of basis weight was 0.06 kg.
/ M ² . On another sheet of the obtained fiber mat, 15 parts by weight of urea resin was adhered to 100 parts by weight of the fiber mat in terms of solid content. Next, the fiber mat to which the urea resin is adhered is cut at the center in the longitudinal direction, and is superimposed on two layers, and then subjected to thermocompression molding at 170 ° C. for 8 minutes to have a thickness of 9 m.
m of fiberboard was obtained. The average density of the obtained fiberboard is 0.5
0 g / cm ³ , standard deviation of density is 0.015 g / cm ³
Met.

[Comparative Example 1] Oil palm fibers were spread two-dimensionally on a 2.2 m-wide supply conveyor, and the two-dimensionally spread oil palm fibers were entangled with a needle punch device to obtain 2.2 m wide x 4 m fibers. I got a mat. Both sides of the obtained fiber mat were cut off by 10 cm and cut at the center in the width direction to obtain two 1 m × 4 m fiber mats. As a result of examining the average basis weight and standard deviation of one obtained fiber mat, the average basis weight was 1.81 kg / m ² ,
The standard deviation of the basis weight was 0.17 kg / m ² . On another sheet of the obtained fiber mat, 15 parts by weight of urea resin was adhered to 100 parts by weight of the fiber mat in terms of solid content.
Next, the fiber mat to which the urea resin was adhered was cut at the center in the longitudinal direction, layered in two layers, and then subjected to thermocompression molding at 170 ° C. for 8 minutes to obtain a fiber board having a thickness of 9 mm. The average density of the obtained fiberboard 0.49 g / cm ^3, the standard deviation of the density was 0.039 g / cm ^3.

[0056]

As described above, according to the method for producing a fiber mat of the present invention, a fiber mat having a uniform basis weight can be provided.
Further, according to the method for producing a fiberboard of the present invention, it is possible to provide a fiberboard having high strength, good air permeability, and uniform density, which is passed through a windproof layer.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view showing an embodiment of a fiber mat of the present invention.

FIG. 2 is a schematic perspective view showing an embodiment of a fiberboard according to the present invention.

FIG. 3 shows an apparatus 1 for producing a fiber mat according to the present invention.
It is explanatory drawing which shows an example.

FIG. 4 is an explanatory view showing one example of an apparatus for producing a fiberboard according to the present invention.

FIG. 5 is an enlarged perspective view of a main part showing an example of a knitted fabric laminated on a fiber mat.

[Explanation of symbols]

 Reference Signs List 1 fiber mat, 2 fiberboard, 3 cloth, 4 supply conveyor, 5 hopper, 6 upper condenser, 7 lower condenser, 8 compression roll, 9 discharge conveyor, 10 needle punch device, 11 conveyor 12 spray gun, 13 drying device, 14 Cutting device.

Claims (7)

[Claims] 1. A method for producing a fiber mat comprising the following steps (a) to (c). (A) A step of spreading palm fibers two-dimensionally. (B) A step of compressing the coconut fibers spread in a plane by sucking them from the back surface side of the porous substrate so as to be adsorbed on the surface of the substrate. (C) a step of intertwining the coconut fibers that have been spread and compressed in a plane with a needle punch. 2. The method for producing a fiber mat according to claim 1, wherein the coconut fiber is a fiber defibrated from oil palm. 3. A fiber obtained by adhering a curable resin to the fiber mat obtained by the production method according to claim 1 or 2, drying the fiber mat if necessary, and laminating one or more of the fiber mats and compression-molding the fiber mat. The method of manufacturing the board. 4. A curable resin is adhered to the fiber mat obtained by the production method according to claim 1 and, if necessary, dried, and then the curable resin is adhered to one or more of the fiber mats. 1 of sheet material such as knitted fabric or nonwoven fabric
A method of manufacturing a fiberboard in which one or more sheets are laminated and compression molded. 5. It is produced by the method according to claim 1 or 2, having an average basis weight of 1.2 to 2.5 kg / m ² and a standard deviation of 0.03 to 0.15 kg / m in standard deviation. m
Fiber mat that is ² . 6. A fiberboard produced by the method according to claim 3 and having a bending strength of 3 to 50 N / mm ² . 7. A moisture permeability coefficient of 0.1 to 10 μg / (m ² ·· m
s · Pa).