JPS6135938A - Manufacture of thick layer type filamental molded layer body - Google Patents

Abstract

PURPOSE:To obtain a thick layer type molded body with uniform density, by a method wherein mixed raw materials which is formed by mixing binders to filamental material is filled in bottom force dividing into the prescribed volume, and after the processing said materials by top force for every filling, catalytic gas is flowed through binders. CONSTITUTION:Mixed raw materials M which are formed by mixing binder which is cured by catalytic gas and filamental material, are prepared, and about 1/3 volume of raw materials M are filled in a layer condition in a botton force 2 to which a frame body is attached, and a top force 10 is made to lower and said materials M are pressed with the prescribed surface pressure, and the first compressed layer body is formed. Next, the top force 10 is released, and the filling of materials M and the compressing process are reinterated, and after the second and the third compressed layer body MA2, MA3 are formed to the layer type successively, catalytic gas G is introduced in a hollow room 11 of the top force 10, and in the meantime gas G is absorbed from in a hollow room 3 of the bottom force 2, and binders in the raw materials M are solidified. Hereby, thick layer type filamental molded layer body having uniform density will be possible to be manufactured in a body.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a method for producing a thick fibrous molded layer, and more specifically, it relates to a method for producing a thick fibrous molded layer for use as wall and floor materials for houses, interior materials for vehicles, etc. The present invention relates to an improved method for producing a layered fibrous molded layer.

(Prior Art) Previously, the present inventor invented a good manufacturing method in research for obtaining a fibrous molded layer (Japanese Patent Application No. 58-33431). That is, the gist of this early invention was to mix a catalytic gas-curable binder with a fibrous material to form a mixed raw material, fill it into a mold, close the mold, and pass a curable catalyst gas into the mold. The binder is reacted and cured, and the fibers are bonded and molded to obtain a molded layered body. This manufacturing method has the advantage of being able to be carried out at room temperature; however, if the molded layer is thick, there will be density differences within the layer, making it impossible to achieve a uniform density, and the lower mold frame and equipment will be larger, resulting in longer exposure to light. There was a point.

(Problems to be Solved by the Invention) However, the present invention is an attempt to solve the problems of the earlier invention described above. An object of the present invention is to provide a method for manufacturing a fibrous molded layered body, which yields a fibrous molded layered body.

Furthermore, the present invention provides a manufacturing method for producing a thick-layer type fibrous molded layer body consisting of a high-density layer portion and a low-density layer portion by actively creating a density difference in the thick layer body, such as the surface layer portion and the inner layer portion. It is about providing.

(Means for solving the problem) Therefore, as a result of further research, the present inventor obtained good results and achieved the present invention. A predetermined amount of a mixed raw material obtained by mixing a fibrous material and a fibrous material is filled in a thick layer in a lower mold for molding, and then the mixed raw material is compressed using an upper mold for compaction to produce a compressed mixed raw material. In order to obtain a cured molded product of the mixed raw materials by flowing a catalyst gas through the raw materials, (a) Fill the lower mold with an appropriate amount of the predetermined amount of the mixed raw materials in a layered manner and compress it with the upper mold; Open the mold, fill the remaining mixed raw material in a layer on the compressed layer body of the lower mold, and compress it in the upper mold, or (b) or repeat filling and compression to fill a predetermined amount of the mixed raw material in a layer. The catalytic gas is compressed in an upper die and then allowed to flow through the entire compressed layered body.

(Function) In the present invention, the predetermined amount of the mixed raw material to be filled into the lower mold in a thick layer is not filled into the lower mold for molding at once, but is filled in multiple times. That is, an appropriate amount of the predetermined amount of the mixed raw material is first filled in a lower mold in a layered manner, compressed in an upper mold to form a first compressed layer, and on this first compressed layer. The remaining mixed raw materials are filled in a layer and compressed with an upper mold.
This is the second compressed layer body. The first type depends on the degree of compression pressure of the upper mold.
and the second compacted layer may have the same density or different densities. Next, the binder mixed in the first and second compressed layer bodies is solidified by a catalyst gas, and both layers are bonded together to form a molded layer body of the glue layer.

(Example) First, an example of an apparatus used to carry out the method of the present invention will be described with reference to the drawings.

FIG. 1 shows a molding die 1 for forming a thick molding layer body, which mainly consists of a lower mold 2 and an upper mold 10. As shown in FIG. The lower mold 2 has a hollow chamber 3, and the upper part thereof serves as a molding surface 4. The molding surface 4 is provided with small diameter gas flow holes 6 to 6 communicating with the hollow chamber 3, and the molding surface 4 is provided with gas flow holes 6 to 6 on the outer periphery of the molding surface 4. A fitting portion 5 is formed into which a cylindrical frame 9 is removably fitted. 8 is the lower mold 2
A gas suction means equipped with a suction pump placed nearby and connected to the hollow chamber 3 of the lower mold 2 via a connecting conduit 7 absorbs the catalyst gas in the hollow chamber 3 and neutralizes it with a neutralizing liquid. It is like that.

The lower end of the frame 9 can be press-fitted into the fitting part 5 of the lower mold 2, and has a sufficient height so that the upper mold 10 can be inserted after the mixed raw material M is filled.

The upper mold 10 has a size that allows it to be inserted tightly into the frame 9, has a hollow chamber 11, and has a molding surface 12 on the lower side. 13-1
3 is installed through it. And upper mold 1 is on top of upper mold 1-0.
0 is connected to a gas supply means 15 for the catalyst gas G via a flexible connecting conduit 14 of sufficient length to allow the gas to descend;
When curing the binder of the compressed mixed raw material M, the catalyst gas G in the gas supply means 15 is sent to the hollow chamber 11 of the upper mold 10, and after the catalyst gas G is supplied, air is sent. There is.

Next, a first method for producing a thick layered body using the mold 1 of this example will be described.

First, a mixed raw material (molding raw material) M made by mixing a fibrous material and a binder is prepared. Examples of fibrous materials include fibrous bodies produced from wood, clothing, waste paper, etc., or 41 fibrous materials such as wood flour, rice husk flour, pulp flour, etc.
The binder uses polyol and isocyanate, for example, 50 parts by weight of lauan wood fibers with an average fiber length of 5 m (
Hereinafter, it will simply be abbreviated as part. ), 50 parts of wood flour of 40 to 60 mesh, and 10 parts of isocyanate-based prepolymer (trade name "UT-48004" manufactured by Gunei Chemical Industry Co., Ltd.) were added and stirred to obtain a mixed raw material M.

Thus, a predetermined amount of the mixed raw material M for obtaining a thick-layer molded layered body is prepared, and the mixed raw material M is placed in the lower mold 2 to which the frame 9 is assembled.
The amount of about 173 is filled in a layer (see Fig. 2). Then, the upper mold 10 is inserted into the frame 9 and lowered, and the surface pressure is 40Ky/
A first compressed layer body M compressed by CD and having a thickness of about 3311I11
A1 (see Figure 3).

Next, the upper mold 10 is raised to open the upper part of the frame 9, and about 1/3 of the mixed raw material M is filled into the frame 9 in a layered manner (the fourth
(see figure). After that, the upper mold 10 is lowered into the frame body 9,
Compressed with a surface pressure of 4ONIF/7, the second piece has a thickness of about 33#lI.
A compressed layered body MA2 is used (see FIG. 5).

Next, after lifting the upper mold 10, the remaining mixed raw material M is placed in the frame 9.
(see Figure 6), and the upper mold 10 is placed under a surface pressure of 40
While suppressing and holding at Kg/ci to form the third compressed layered body MA3 and sending the catalyst gas (triethylamine) G from the gas supply means 15 to the hollow chamber 11 of the upper mold 1o, the gas suction means 8 is operated to lower the The inside of the mold 2 hollow chamber 3 is sucked.

Thus, the catalyst gas G in the 1° hollow chamber 11 of the upper mold passes through the compressed layer bodies MAI to MAS, reacts with the binder mixed in the mixed raw material M, and solidifies the binder. After the catalytic gas flows through for 5 minutes at normal temperature, the supply of the catalytic gas G is stopped, the gas supply means 15 is switched to supply air, the excess gas is replaced with air, and then the upper mold 10 is raised and the frame 9
is removed to obtain a molded product with a predetermined thickness, that is, a molded layered body MA (see FIG. 8). This molded layered body MA had a thickness of 96 mw and a density of about 0.8 g/C13, and the intestinal tissue was in a good uniform state.

Similarly, a case will be described in which the mold 1 is used to obtain molded layered bodies with thick layers having different layer densities.

The first mixed raw materials include 50 parts of lauan wood fiber with an average fiber length of 5IIIR, 50 parts of 150 mesh wood flour, and isocyanate prepolymer "tlL-4800J1".
A mixture with 0 parts was prepared. and 50 parts of lauan wood fiber with an average fiber length of 5#III as a second mixed raw material,
A mixture of 40 to 60 mesh of wood flour and 10 parts of isocyanate prepolymer 1"IIL-4800 was prepared.

Approximately 1/2 of the first mixed raw material is then filled in layers in the lower mold 2 with the frame 9 assembled, and the upper and lower molds are pressed against a surface pressure of 40 m/s.
First compressed layered body MB1 compressed by cd and having a thickness of 10jI+
He said. Next, the upper and lower molds were opened, and the second mixed raw material was filled in layers, and the upper and lower molds were compressed at a surface pressure of 40 and 9/cd to form a second compressed layered body MB2 having a thickness of 20 is+. Then, the upper and lower molds are unraveled, the remaining amount of the first mixed raw material is filled in layers on the second compressed layer body MB2, the upper and lower molds are compressed with a surface pressure of 40 Ky/cd, and a third compressed layer with a thickness of 10 m is formed. After forming a body MB3 and holding it under compression, a catalyst gas (triethylamine) was passed through the body for 3 minutes, and the excess gas was replaced with air, a thick layered molded product, that is, a molded layer body MB was obtained (see FIG. 9).

This molded layered body MB has a thickness of 40 m and an average density of 0.82 g/
C113, and the first compressed layer body MB1 and the third compressed layer body MB1 on both sides
The second compressed layer body MB is intermediate to the structure of the compressed layer body MB3.
2 has a three-layer bonded structure with a rough texture.

In the above-mentioned embodiments, a case was explained in which the mixed raw material was charged into the mold in three parts to obtain a thick layered layered body, but the present invention is not limited to this, and the mixed raw material was filled in two parts.
It can be changed more than once as needed. In addition, the compression pressure of the upper and lower molds after filling the mixed raw material is the first filling amount and the second filling amount.
If the first compression tR1 is the same and the first and second compression pressures are the same, both layers will have a uniform structure, and if the compression pressure is changed, both layers will have a uniform structure. may be of tissue of different density, and the compression pressure may be varied as required.

Furthermore, in the above embodiment, the binder and the catalyst gas for curing are cured by a urethanization reaction using an amine-based catalyst gas for the binder made of polyol and polyisocyanate, but the binder and the catalyst gas are limited to this. Instead, a curing agent of sulfuryl chloride may be used in gas or aerosol form for a binder made of acid-curing resin such as urea/formaldehyde resin, phenol/formaldehyde resin, or furan resin. An acid-curing resin with an oxidizing agent added thereto can be used in the form of sulfur dioxide in the form of a gas or aerosol, and for a binder of sodium silicate, an acidic gas such as carbon dioxide can be used for curing.

(Effects of the Invention) The present invention comprises layering and compressing an appropriate amount of a predetermined amount of mixed raw materials for forming a thick layer, layering and compressing the remaining mixed raw materials on the compressed layer body, Or, after repeating filling and compression as necessary, in a compressed state,
In order to allow the catalyst gas for binder assimilation mixed with the mixed raw materials to flow through, both compressed layer bodies are adhesively molded to obtain a thick-layer molded layer body. That is, in the present invention, when filling a lower mold with a predetermined amount of mixed raw materials, the process of filling the predetermined amount in portions and compressing it in the upper mold each time is repeated.
When the filling amount and compression conditions are the same, a thick layered body with the same density is formed, and when the filling amount and compression conditions are changed, a thick layered body with different densities is obtained. It is something that can be done.

In addition, since the present invention fills the lower mold body with the mixed raw material by repeating filling and compression, the height of the lower mold body can be reduced, and the clamping pressure of the upper mold can be reduced, making the entire apparatus more compact. It has the advantage of being downsized.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing an example of a molding apparatus used for implementing the present invention. Figures 2 to 8 show the implementation steps of the first embodiment, in which Figure 2 is a filling flow process diagram of mixed raw materials, Figure 3 is a process explanatory diagram showing the first compression process, and Figure 4 is a process diagram showing the first compression process. 5 is a process diagram showing the second compression process, FIG. 6 is a diagram showing the third compression process, and FIG. 7 is a diagram of the third compression process. Process explanatory diagram showing the process, No. 8
The figure is a perspective view of the molded layer body. FIG. 9 is an enlarged sectional view of the molded layer obtained in the second example. 1... Molding mold 2... Lower mold 3.1
1...Hollow chamber 4, 12...Molding surface 5
...Fitting part 6,13...Gas circulation hole 7.
14... Connection conduit 8... Gas suction means 9
...Frame rest 10...Top mold 15.
...Gas supply means M...Mixed raw materials HA, HB.
... Molded layer G... Catalyst gas castle (Y) ('Jr- r-'\-\ J19

Claims (1)

[Claims] A predetermined amount of a mixed raw material made by mixing a binder that hardens with a catalyst gas and a fibrous material is filled in a thick layer in a lower mold for molding, and then the mixed raw material is filled using an upper mold for pressing. compress,
When a catalyst gas is made to flow through the compressed mixed raw material to obtain a cured molded product of the mixed raw material, an appropriate amount of the predetermined amount of the mixed raw material is filled into a lower mold in a layered manner, and after being compressed in an upper mold, Open the lower mold, fill the remaining mixed raw material in a layer on the compressed layer body of the lower mold, and compress it in the upper mold, or repeat filling and compression to fill a predetermined amount of the mixed raw material in a layer, and then fill it in the upper mold. 1. A method for producing a thick layered fibrous molded layered body, comprising: compressing the layered body, and then causing a catalyst gas to flow through the entire compressed layered body.