JPS6261702B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for preparing felt fiber materials, which effectively improves the properties of felt fiber raw materials, and which can be applied to any desired degree from soft cushioning materials to hard materials. The purpose of the present invention is to establish a method for preparing felt fiber materials that can freely obtain felt materials having the above-mentioned properties and that can economically and accurately produce such felt materials.

Felt is made into a plate-like material by needle-processing fibrous material, which is like fiber waste, but simply needling the fibrous material does not allow for proper binding and integration between the fibers. It is common to mix a binding component such as a resin component to achieve a certain level of binding between the fibers. In other words, there are various methods for blending such binding components, such as a spray method, an impregnation method, a powder method, and a fiber method, and even though each of these methods has its own characteristics, they all require a large amount of man-hours. , disadvantages such as higher costs cannot be avoided. The lid spray method involves spraying the binding component in liquid form and attaching it to the fibers. The first step is to add a sufficient amount of water or other solvent to the viscous binding component to make the dispersed particles finer. It takes a long time, and no matter how finely divided the material is, and no matter how much ventilation is used to penetrate and adhere to the tissue, the inside of the cotton-like fiber material, which is a mass of fine fibers, cannot be penetrated into the tissue. It is not possible to achieve even attachment. On the other hand, the impregnation method involves dipping the cotton-like fiber material in an adhesive liquid and attaching it to the adhesive, and even if it does not require the painstaking effort to create a fine atomization, the adhesive is deposited within the fine fiber structure. The difficulty of uniformly dispersing and adhering the adhesive is equal to or greater than that of spraying due to the necessity of squeezing after impregnation, and it is also necessary to use a sufficiently diluted and low-concentration adhesive. It is the same as a spray and requires a long time to diffuse. The above-mentioned powder method and fiber method have been proposed to overcome the disadvantages of using such liquid adhesives. Even if the disadvantages of dissipating large amounts of other solvent components could be overcome, it would still be difficult to evenly mix such powders and fibers into large amounts of felt material nodules; Since it is necessary to heat and melt the powder or fibrous binding component after that, the powder or fibrous binding component is a special resin material that melts at a low temperature. It is much more expensive than felt raw material fibers, and is generally more than 10 times more expensive, which inevitably leads to higher costs.Furthermore, no matter how evenly mixed, such powder or fibrous binding components Since these are only partially mixed in the form of dots or lines, there is a drawback that the felt fastening texture effect determined by the unit amount of the binding component blended is poor.

The present invention was created through repeated research to eliminate the disadvantages and shortcomings of the conventional products as described above. In other words, in the present invention, in view of the fact that no matter how much efforts are made to achieve fine atomization in the conventional spray method as described above, uniform adhesion cannot be obtained, and in view of the fact that no matter how much effort is made to achieve fine atomization in the conventional spray method, even adhesion cannot be obtained in the end. By passing this through a conveyance process using suction or pressure-feeding gas, the conveyance process (hereinafter referred to as pneumatic conveyance process) is used to disperse and disperse the fibers to which the binding component is attached and the fibers to which the binding component is not attached. It is proposed that mixing is achieved through subsequent deposition, and then beating treatment is performed to further stretch and propagate the binding components attached to the fiber surface. There is no need to further dilute the liquid binding component in order to reduce the amount of water and achieve sufficient dispersion and atomization, and it can be used as a highly concentrated product. The difficulty of the aeration process is eliminated at once, and the stretching and propagation of the binding component by the beating and stretching process is optimized. Even if it remains highly concentrated, it contains a certain amount of water and other solvent components since it is in a liquid state, but this amount is generally less than 50% and the remainder is non-volatile matter. Moisture etc. can be treated with almost no difficulty in the process, and even if thorough beating and stretching treatment is performed, the process time can be sufficiently shortened to complete the desired adjustment process in about 2 to 3 minutes. can do.

Further, in the present invention, after the binding component is stretched and propagated by the beating and stretching treatment as described above, an organic or inorganic powder such as starchy powder or silica sand powder is sprinkled and the same beating and stretching treatment is performed again. .

That is, the binding component attached to the fiber surface as described above exhibits a considerable adhesive effect, especially when the amount thereof is relatively large, and if left as it is, it will cause problems in subsequent needle processing to make felt. However, the powder dispersed as described above adsorbs moisture and other fluid components to reduce the adhesive effect and allow needle processing to be carried out without any hindrance. When starchy powder is used, it is subjected to heat treatment after the needle processing to strengthen and increase the fastening effect of the adhesive component which acts with adsorbed water and exhibits gelatinizing effect. Even if silica sand, borax, and other inorganic powders do not produce such a gelatinization phenomenon, they will still contribute to the flame retardant effect in the resulting product.

The specific embodiments of the present invention will be described with reference to the accompanying drawings. The raw materials for felt cotton fibers (generally a mixture of fibers such as cotton, synthetic fibers, wool, rayon, etc.) obtained from textile processing factories etc. ) is spread in a layer of about 10 to 30 mm in the mixer 1, and the binder 2 is sprinkled on this.
Items in this state are stacked and stored. In the case of the present invention, as mentioned above, it is not intended to achieve uniform adhesion in this step, so there is no need to take particular pains to control the thickness of the fiber layer or the amount of the sprayed binder 2, and of course There is no need to be particular about the performance of the nozzle or spray mechanism, and it is sufficient to laminate the layers according to a rough guideline.
Facing the blender 1 is a suction tube 4 with a built-in fan 5, which sucks in air under negative pressure, but may also be under positive pressure conditions depending on the case. The suction pipe 4 performs a suction action by driving the fan 5, and suctions the fibers in the blender 1 together with the dispersed binder. Air flows in a vortex or turbulent manner within the suction tube 4, and while the individual fibers are carried along with this airflow, the accumulated fibers are appropriately dispersed and mixed. In particular, the fan 5 is provided with a scratching claw 5a at the tip of its rotor blade, which effectively disperses and transports the fibers being fed, even though the duct 6 behind the fan 5 is under high pressure. This relationship is the same. In any case, in these processes, the fibers to which the binder has been attached and the fibers to which the binder has not been attached are mixed substantially evenly and transported.

The binders used are melamine, urea, and phenol, and copolymers of these are widely used, but when particularly hardened performance is desired, vinyl acetate or vinyl acetate are used. A copolymer with it is used in liquid form. In some cases, flame retardants such as diammonium phosphate salts themselves have a certain degree of tackiness and can be used as a binder. A material mainly composed of the above-mentioned melamine resin provides preferable water resistance. In the case of the present invention, it is not strictly prohibited to incorporate a solvent, but it is not preferable to dilute with a large amount of solvent as in the conventional spraying method or dipping method. That is, in the present invention, these cutting components are diffused during the pneumatic feeding process, and in particular, are drained while passing through the Net Box 7, etc., which will be described later. Since the dispersion of solvent components such as water is much easier and faster than in the case of the method, it is not particularly inconvenient to dilute it by a little cutting, but there is no advantage to using a large amount of diluted material. Generally, it is applied at a higher concentration than when using spray methods. Also, mixing a flame retardant into such a binder is very effective in imparting a flame retardant effect to the resulting product, and the product produced by the method of the present invention is relatively flexible. If it is like a cushion material, it can be used as a soundproofing material or a heat insulating material.
Materials that are slightly harder than this can be used as carpets for automobiles and buildings, and even harder plywood-like materials can be used as general building materials, especially as not only the inner layer material but also the surface material by using a water-resistant binder. In both cases, it exhibits a favorable flame retardant effect. In addition, such flame retardants (for example, those based on diammonium phosphate) generally reduce the viscosity of the above-mentioned resin-based binders, so they are also advantageous in terms of processing. Powdered materials such as starch and silica sand may also be blended here in some cases.

A net box 7 is connected to the downwardly bent end of the duct 6 as described above, and this net box 7 prevents the air-fed fibers from scattering and connects them to the lower conveyor. 8
Furthermore, the high pressure condition in the duct 6 is released to create a normal pressure flow, and at this time, the water contained in the gas is also discharged to the outside. At the rear end of the conveyor 8 are two groove cutting rolls 9, 9, which sequentially sandwich the fibers sent by the conveyor 8 and feed them into the cylinder 10 at the rear. This cylinder 10 is provided with a beating drum 11 having scraping claws 11a arranged on the circumference of the drum. The fibers are rotated at a high speed, and the fibers are sandwiched at the rear end by grooved rolls 9, 9 and sent into a cylinder 10, which can also be called a blender, and subjected to a beating and drawing process. In other words, the fibers that have grown out are struck by the scraping claws 11a and pulled in the direction of rotation, and at this time, the binder attached to the fibers as described above is also stretched so as to flow with the comb teeth. The adhering binder is distributed in the length direction of the fibers, and is transferred onto adjacent fibers by the tapping pressure when the scraping claw 11a comes into contact with the fibers, and is similarly stretched in the length direction of the fibers. By receiving the action of the scraping claw 11a that rotates continuously at high speed in this way, almost uniform adhesion of the binder to most of the fibers can be achieved, which also improves the adhesion distribution state in the length direction of the fibers. It will be completed including

In the illustrated embodiment, the above-mentioned operational relationship is applied repeatedly, that is, the cylinder 10 is connected to a duct provided with fans 12 and 13 with lifting claws, and the fan 13 is connected to a duct provided with lifting claws. A duct 14 is provided, and after the dispersion and mixing during pneumatic feeding as described above is repeated, the material is dropped into a net box 15. A horizontal conveyor 15a with feeding claws arranged on the lower side of the net box 15
is provided to sequentially send out the falling fibers in the same way, and sandwich these fibers between the groove cutting rolls 16 and 16 to the next blending cylinder 17a.
, the scraping claws 17 are finer than the drum 11.
After being subjected to similar beating and combing by the rotation of the drum 17 having the rotation speed b, it is placed on the conveyor 24.

A dusting drum 18 is provided on the conveyor 24, and a suitable quantity and quality of powder is scattered in consideration of the viscosity of the adhesive used. Regarding this powder, as described above, a starch-based or siliceous powder is supplied from one end of the dusting drum 18 and is dispersed. No. 3 cylinder 25 receives the beating and combing effect from the drum 20 having scraping claws while being held by the groove cutting rolls 19, and falls onto the conveyor 21 below, where it is carried upward by the conveyor 21. Netstrol 2 made of wire mesh
At step 2, the adjusted fibers are delivered onto the delivery table 23.

Specific examples of the method of the present invention will be described below.

Example 1 A known felt fiber material obtained from a textile processing factory was conditioned using the apparatus shown above.

The material used as a binder is resin content (solid content).
is a melamine urea phenol copolymer resin liquid containing approximately 68%, and this is added to the blender 1 at a concentration of 3% by weight to the above fiber material arranged in a layer of approximately 15 mm.
Separately, a mixture of 16% by weight of a diammonium phosphate flame retardant and a small amount of an ammonium chloride catalyst is alternately sprayed and conveyed by suction pipe 4, and dispersed and mixed during the conveyance process. Then, beating and stretching were performed in cylinders 11, 17a, and 25, respectively. Each belt conveyor 8,1 with a width of 1200mm
The transfer speed at 5a and 24 is about 15 m/min, the peripheral rotational speed of the drum 11 is about 1200m/min, and the peripheral rotational speed of the drums 17 and 20 is about 800m/min. The fiber material was treated by sprinkling 5% by weight of silica sand, and the entire process was carried out at approximately room temperature.
The processing speed is approximately 400% under the above conditions.
Kg/hr, and approximately 4% of the fiber material was lost due to the pneumatic conditions during the entire treatment process, but since the binder and other substances were added as mentioned above, the treated fiber The amount produced in this way is about 430 kg per hour, and the material obtained in this way is sent to a felt manufacturing equipment where it is needle-processed and then heated at 160-170℃.
By adding approximately 30% hot pressing at a temperature of 30%, the felt becomes cushiony and suitable for use in disaster prevention head cloths and other disaster equipment.

Example 2 All treatments were carried out under the same conditions as in Example except that the melamine urea phenol copolymer resin as described above was used as a binder at about 20% by weight of the fiber material and the flame retardant was used at 15% by weight.

Approximately 445 processed fibers are obtained per hour.
After needling, this material can be hot pressed to reduce the thickness after needling by about 30% to make felt suitable for use as automatic rugs.

Example 3 Vinyl acetate liquid binder (solid content approximately 50%) was applied to the same felt fiber material as in Examples 1 and 2.
35% by weight and the same flame retardant as in Examples 1 and 2
All treatments were carried out in the same manner as in Examples 1 and 2, except that in the dusting drum 18, 5% by weight of the starch-based powder and 5% by weight of the silica-based powder were spread. .

The obtained preparation has a thickness of 70 mm after needle processing.
By hot pressing to compress the material, a plate material suitable for use as a core material for buildings could be obtained.

According to the present invention as explained above, the fibers to which the adhesive is attached and the fibers to which the adhesive is not attached are appropriately mixed by spraying and adhering the adhesive to the felt fiber material and then dispersing and mixing it under pneumatic conditions. Furthermore, during the subsequent beating and stretching process, the adhesive deposited on the fibers is spread and stretched onto the fibers located in the length direction and circumferential side of the fibers, and the adhesive is spread onto the fibers and evenly spread onto the hair. A state of uniform distribution and adhesion that cannot be obtained with conventional methods is achieved by forming a development and adhesion relationship similar to that in which the hair conditioning liquid etc. is evenly applied to the entire hair by combing or brushing. Therefore, the quality and properties of the felt fiber itself can be greatly improved by the adhesive attached to the fiber surface in this way, and the well-known needle processing and hot press processing can be completely removed from the felt. By adjusting the degree of processing, the effects of both of these treatments can be obtained significantly, and by adjusting the degree of processing, it can be made harder than conventional felts. , it will be possible to freely obtain a variety of products such as bulkier and more flexible materials or harder materials for construction, and it will greatly change the aspect of felt products and expand the range of demand for them. In addition, the adjustment process can be carried out continuously and with high efficiency, and in this respect, it has the effect of bringing about a major change in the felt manufacturing industry, and is an invention with great industrial effects. be.

In addition, in the case of spraying plant-based organic powder or inorganic powder such as silica sand in the present invention, especially when a highly viscous adhesive is used, the viscosity of the applied adhesive is reduced and then Needle processing can be carried out without any trouble, and the hardening properties can be increased during subsequent hot press processing, or flame retardant properties and other properties can be obtained by using a powder material. It is also an invention with great industrial effects.

[Brief explanation of the drawing]

The drawings illustrate embodiments of the invention,
FIG. 1 is an explanatory diagram showing one example of the adjustment processing equipment designed according to the present invention, FIG. 2 is an explanatory diagram of the scraping claw for the first drum, and FIG. It is an explanatory view of a handle. In this drawing, 1 is a blender, 2 is a suction tube, 4, 12 and 13 are fans, and 7 and 15
9, 16 and 19 are groove cutting rolls, 8, 15a and 24 are conveyors,
Reference numerals 11, 17 and 20 indicate drums with scraping claws, 18 a dusting drum, and 22 a net roll.

Claims (1)

[Scope of Claims] 1. A sticky liquid is applied to the cotton-like fiber raw material by spraying and then mixed by pneumatic dispersion, and then sandwiched between rolls and subjected to beating and stretching treatment using a rotating drum having scraping claws. 1. A method for adjusting a felt fiber material, which is characterized in that a sticky liquid is evenly spread and adhered to the peripheral surface of the fibers. 2. The sticky liquid is sprayed onto the cotton-like fiber raw material, and then mixed by pneumatic dispersion, and then sandwiched between rolls and beaten and stretched using a rotating drum having scraping claws to remove the adhered sticky liquid around the fibers. 1. A method for preparing a felt fiber material, which comprises the steps of uniformly developing and adhering the fiber material to a surface, and then dispersing the powder, followed by beating and stretching again to ensure the dispersion and adhesion of the powder.