JPS59204530A - Preparation of three-dimensional molded article - Google Patents

Abstract

PURPOSE:To make it possible to obtain a three-dimensional molded acticle having a complicated shape, by laminating a fibrous substance onto a three-dimensional mold formed by curving a metal net or other air permeable materials while molding the laminated fibrous substance by the clamping force of a female and male molds. CONSTITUTION:A molding material 4 based on a fibrous substance, in which an appropriate binder is mixed and added, is accumulated on a three-dimensional mold 3, which comprises a metal net or other air permeable materials each curved and formed into a shape almost same to the molding surfaces 1a, 2a of a female and a male mold materials 1, 2, over the entire surface thereof in an almost uniform thickness. This mold 3 is placed so as to be inlaid with the lower mold material 2 of a press and, thereafter, the press is operated to perform compression molding. As mentioned above, because the molding material is accumulated on the mold comprising the air permeable material such as the metal net, laminating work can be easily performed and the lamination thickness of the molding material can be brought to a desired thickness over the entire surface of the mold.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a deep-drawn three-dimensional molded product made of a fibrous material.

BACKGROUND ART Products molded using mineral fibers such as rock wool or vegetable fibers such as pulp have been widely known.

For example, heat insulating and cold insulating tubes are known as typical products molded from mineral fibers such as glass wool and rock wool, but these are made by adding adhesive to fiber materials and forming them into a cylindrical shape. Although it is possible to mold such a simple shape, it is difficult to obtain a three-dimensional molded product with a complicated shape.

On the other hand, base molded products made mainly of vegetable fibers are used for car door trims, furniture surface materials, etc. due to their strength, but when manufacturing three-dimensional molded products with complex shapes, This is called the wet t-rudyshik method and requires the use of a large amount of water, so a large amount of energy is required. □ The present invention has been made in view of these problems, and involves making a three-dimensional mold by bending and forming a wire mesh or other breathable material in advance to match the shape of the mold surface of the molding material. , provides a method for producing a three-dimensional molded article, which is characterized in that a fibrous material is laminated to an appropriate thickness on this three-dimensional mold, and then pressed and molded with male and female mold materials.

To explain the embodiment of the present invention with reference to the drawings, the shape is approximately the same as the mold surfaces (la) and (2a) of a pair of upper and lower female and male mold members (1) (2) attached to a vertically movable press (not shown). A molding material (4) whose main raw material is a fibrous material mixed with an appropriate binder is placed over the entire surface of a three-dimensional mold (8) made of a wire mesh or other breathable material, which is curved in shape. Deposit to approximately uniform thickness.

In order to deposit the molding material (4) on the three-dimensional mold (8), the molding material (4) is sprayed together with air onto the three-dimensional mold (8), and only air is applied to the three-dimensional mold (8). It may be deposited by passing or as shown in FIG.
Spreading the molding material (4) from above the mold (8),
A method of suctioning from below the mold may be used, or a combination of both methods may be used.

The fibrous material that is the main raw material of the molding material (4) is as follows:
Mineral fibers such as rock wool and glass wool and vegetable fibers such as pulp are used.

These fibrous substances may be used as fibers alone, but they may also be mixed with lightweight aggregates such as perlite, calcium carbonate, limestone, etc., and even natural fibers such as cotton fibers. Further, an appropriate binder is added to these fibrous materials.

As the binder, phenol resin, urea resin, vinyl acetate resin, or other synthetic resins with adhesive properties, or natural binders such as starch are used. , may be used in any form. Also, mold (3)
When depositing on the molding material, this binder may be mixed in advance with the molding material, or may be supplied to the molding die (3) in the form of a mist together with the molding material. Alternatively, a fibrous material may be uniformly fixed with a binder in water and then dehydrated.

In this way, the molding material (
4), the molding die (8) is fitted into the lower molding material (2) of the press and placed thereon, and then the press is operated to perform compression molding.

At this time, depending on the synthetic resin added to the molding material (4), it may not be necessary to heat the mold materials (1) and (2), but there is no problem in heating them to shorten the molding time. .

In addition, if a thermosetting resin is used as the binder added, or if it is necessary to evaporate water from the molding material, heat and pressure can be applied using mold materials (1) and (2). be.

Furthermore, if the fibrous material is a mineral fiber such as zero-tsuku wool, it is sufficient to make the surface of the resulting molded object dense enough to allow painting, etc.; Just go. Note that in order to prevent the fibers from being destroyed due to pressurization and clamping of the mold materials, a distasi bar is provided between the male and female mold materials.

On the other hand, in the case of vegetable fibers such as bulp, fiber glue snails,
In order to activate hetricellulose, etc., hot pressing is performed at a high temperature of 160° C. or higher and at a high pressure of 20 Iaj/(n or higher) to obtain a high-strength three-dimensional molded product in the form of a hardboard. 20-40% in vegetable fiber
As long as the amount of moisture is added, only a small amount of vigitor can be used.

In this way, by compressing the upper and lower mold materials (1) and (2), a three-dimensional molded product having a predetermined wall thickness is obtained, and the three-dimensional molded product is tightly attached to the molded product taken out from the mold materials (1) and (2). The mold (8) is peeled off and used for the next molding.

Next, specific examples of the present invention will be shown.

Example 1 87% by weight of powder, 6% by weight of pearlite, and 7% by weight of starch were mixed in water and then dehydrated to give a water content of 10.
A molding material with a concentration of 0% (solid content weight ratio) was blown onto a three-dimensional mold with a W-shaped cross section and made of a 30-mesh wire mesh with a maximum depth of 50 m/m and a central part bulging upward. At the same time, the lower part of the mold was reduced in pressure using a vacuum boss to adsorb the molding material onto the mold, thereby forming a deposited layer of the molding material with a thickness of 20 mm.

Next, this molding material is placed on the lower mold material in a hot press together with the three-dimensional mold, and the upper and lower mold materials G are heated at 100°C.
, 3 to 9/cri for 90 seconds.

It should be noted that the spacing between the upper and lower mold members of this hot press is designed so that, when pressed to a spacing of 15 mm, all parts have a spacing of 15 mm.

As a result, a three-dimensional molded product with a thickness of 15 mm was obtained, and although traces of the wire mesh remained on the lower surface of the molded product, the entire surface was smooth enough to be coated.

Example 2 The same three-dimensional mold as in Example 1 was used, and a fiberboard valve 90 with a water content of 50% in terms of solid content weight ratio was placed on this mold.
A deposited layer of the molding material was formed by spraying a mixture of 10% by weight and 10% by weight of phenolic resin powder to a thickness of 20 μm.

Next, this molding material was placed on the lower mold material in a hot press together with the three-dimensional mold, and heated at 220°C by the upper and lower mold materials.
Conditions were 60-40-20 seconds at a pressure of 30 Yu (thus, molding was performed).

The distance between the upper and lower mold materials of this hot press is 5 tn.
It is designed so that when it is compressed to a distance of 5 m, there will be a distance of 5 m at any part.

The three-dimensional molded product thus obtained has a thickness of 5 fins and a specific gravity of 1.
0, and the strength of the flat plate portion was 9 to 700.

As described above, the present invention uses a fibrous material as a main raw material, to which an appropriate binder is added, on an air-permeable mold such as a wire mesh, which is formed in approximately the same shape as the mold surface of a molding material. It is characterized by laminating the molding material to an appropriate thickness, inserting it between a pair of upper and lower male and female mold materials, and then pressing these mold materials to press or heat or pressurize the molding material. Since it is related to a method for manufacturing a three-dimensional molded product, the molding material is deposited on a mold made of a breathable material such as a wire mesh, which is formed in advance in approximately the same shape as the mold surface shape of the male and female mold materials. Lamination work can be easily carried out, and the thickness of the molding material on the mold can be made to the desired thickness over the entire surface of the mold, and the mold with the molding material laminated can be fitted into the lower mold material. Furthermore, according to the method of the present invention, when the upper and lower mold members are pressed together, the mold can be molded smoothly without any unreasonable deformation pressure being applied to the mold. , without requiring a large amount of energy as in the conventional wet mold digital method.
It also eliminates the need for a drying process, resulting in lower production costs.
Furthermore, since the water content in the molding material is low, the press cycle can be shortened and productivity can be improved.

Further, the molding material may be any fibrous material such as mineral fiber or vegetable fiber, and various molded products can be obtained depending on the degree of heating and pressure applied during pressing of this fibrous material.

[Brief explanation of drawings]

The drawings show embodiments of the present invention; FIG. 1 is a simplified sectional view of a three-dimensional mold, FIG. 2 is a simplified sectional view showing a state in which molding material is deposited on the mold, and FIG. 3 is a molded state. FIG. 4 is a cross-sectional view of the product. (1) (2)... Mold material, (3)... Three-dimensional mold,
(4)...Molding material. Patent applicant: Daiken Kogyo Co., Ltd.

Claims (1)

[Scope of Claims] ■ Molding using a fibrous material as a main raw material to which an appropriate binder has been added, on a breathable mold such as a wire mesh, which is formed in substantially the same shape as the mold surface of a molding material. After laminating the material for molding to an appropriate thickness, this is inserted between a pair of upper and lower male and female mold materials, and then these mold materials are pressed together to pressurize or heat the molding material.
A method for manufacturing a three-dimensional molded product, which is characterized by applying pressure. (2) The method for producing a three-dimensional molded article according to claim 1, wherein the fibrous material is Qm) fural or other mineral fiber. (2) The method for producing a three-dimensional molded article according to claim 1, wherein the fibrous material is pulp, pulp, or other Q vegetable fiber.