JPS63120150A - Dry production of resin felt reduced in dust - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for producing dry resin felt with less dust. More specifically, the present invention uses a powdered phenolic resin that has excellent dust resistance and, if necessary, imparts good powder fluidity, as a binder for the defibrated fibrous base material. , relates to a dry resin felt manufacturing method that suppresses the generation of dust during the manufacturing process.

[Conventional technology]

Conventionally, a fibrous base material such as natural fiber or synthetic fiber is defibrated and resin 1iJ1. After removing the resin binder from heavy equipment, the matte fleece formed by mixing it in a fleece manufacturing machine is transported to a heating furnace (ambient temperature 130-220"C) to completely cure the binder, resulting in cured felt. Alternatively, molded felt obtained by pre-curing (semi-cured felt) and then heating and pressure molding is generally called resin felt. It is used as a variety of industrial materials, such as cured felt, car ceilings, dash boards, and door trims (molded felt).

Usually, fibrous base materials for resin felt include, for example, animal and plant fibers such as wool, silk, cotton, hemp, kapok, and coconut, natural fibers such as asbestos, glass fibers, metal fibers, rock fibers, ceramic fibers, etc. Inorganic fibers such as rayon, recycled fibers such as Cubra, and synthetic fibers such as nylon fibers, vinylon fibers, polyvinylidene chloride fibers, polyethylene fibers, and polypropylene fibers are used alone or in mixtures in arbitrary proportions.

In addition, as the binder for the fibrous base material, thermoplastic resins may be used in addition to thermosetting resins, but thermosetting resins are usually preferably used from the viewpoint of functionality. Powdered phenolic resins such as novolac-type phenolic resin powder, resol-type phenolic resin powder, or a mixture thereof containing hexamethylenetetramine (hereinafter abbreviated as hexamine) have excellent adhesive properties, heat resistance, It has been praised for its mechanical strength and low material cost compared to other thermosetting resins.

Furthermore, in the production of resin felt using the above-mentioned powdered phenolic resin, the fluidity of the powder decreases, especially at high temperatures and humidity, resulting in the resin not being used in the storage tank, the transfer pipe from the storage tank to the resin spreader, or in the resin spreader. Problems such as poor discharge or blockage may occur, and as a countermeasure to this problem, a method is generally adopted in which vibration or shock is applied to the storage tank, transfer pipe, resin spreader hopper, etc. using a vibrator, knocker, etc.

[Problem that the invention seeks to solve]

However, since the powdered phenolic resin is generally a fine powder with a particle size of 74 μm or less, when transferring it to a storage tank or hopper during the production of resin felt,
When spraying from a resin sprayer or when blending or mixing as necessary, phenolic resin scatters as dust and contaminates the work environment, significantly reducing work efficiency, as well as attaching to the human body and causing health problems. There were problems such as environmental health problems such as causing damage, as well as variations in quality and increased manufacturing costs due to the dissipation of phenolic resin.

In consideration of the current situation, the present invention provides a method for manufacturing dry resin felt with less dust, which can maintain a comfortable working environment, improve work efficiency, stabilize quality, and reduce manufacturing costs. The purpose is to provide

In addition, as mentioned above, the method of applying vibration or shock to storage tanks, transfer pipes, resin sprayers, etc. as a countermeasure to the decrease in the fluidity of powdered phenolic resins causes noise that worsens the working environment, and the resin sprayer There were problems such as the time period during which the resin was sprayed was not constant, resulting in variations in product quality.

[Means for solving problems]

The present inventors have investigated the applicability of the dust-proof powdered phenolic resin composition previously disclosed in Japanese Patent Application No. 1982-223782 as a binder for resin felt, and As a result of discovering that surface-treated calcium carbonate has an extremely excellent effect on improving the powder fluidity of the composition,
The present invention has been completed by developing a method for manufacturing dry resin felt with less dust that can solve the problems in the conventional technology.

That is, the present invention provides a method for manufacturing a resin felt by mixing a powdery phenolic resin into a defibrated fibrous base material and then heating and/or heating and press-molding the powdery phenolic resin. A method for producing a dry resin felt with little dust, characterized by using a powdered phenolic resin composition containing a wetting agent and A dry method with less dust, characterized in that a powdered phenolic resin composition containing phenol powder, a wetting agent, and surface-treated calcium carbonate is used as the powdered phenolic resin when producing resin felt by heating and pressing. A method for manufacturing resin felt is provided.

The present invention will be explained in detail below.

The phenolic resin constituting the powdered phenolic resin composition used in the present invention is not particularly limited, and is a solid phenolic resin obtained by heating and reacting at least phenols and aldehydes in the presence of a catalyst. Examples include novolak-type phenolic resins, resol-type phenolic resins, nitrogen-containing resol-type phenolic resins, benzyl ether-type phenolic resins, and modified phenolic resins or any mixed resins thereof. Used in powder form with or without (curing agent).

The phenols include phenol, cresol,
Monohydric phenols such as xylenol, phenylphenol, rose tert-butylphenol, or other alkyl-substituted phenols, or polyhydric phenols such as resorcinol, catechol, hydroquinone, pyrogallol, bisphenol A, bisphenol F1 diphenolic acid, or phenols. Examples include phenolic residues such as resorcinol residues, catechol residues, resol residues, and xylenol residues, which are produced as by-products during the production of phenol residues, and these may be used alone or as a mixture of two or more of them. As the aldehyde, for example, formalin, paraformaldehyde, trioxane, hexamine, or a mixture thereof at various concentrations can be used. It is also possible to use glyoxal, furfural, etc. in combination, if necessary.

The blending amount of aldehydes to phenols in the production of the phenolic resin is selected depending on the type of resin and desired performance; therefore, although not generally limited, in the case of novolac type phenolic resins, 5 to 0.9 mol of aldehyde io per 1 mol of phenol, while in the case of resol type phenolic resin or Hensyl ether type phenolic resin, 1.0 to 5.0 mol of aldehyde per 81 mol of phenol. be selected as appropriate.

The catalyst used in the production of the phenolic resin may be acidic or basic catalysts that have been commonly used, such as hydrochloric acid, sulfuric acid, oxalic acid, inorganic or organic acids such as p-toluenesulfonic acid, M n-Zn%
Carboxylic acid metal salts such as P b and naphthenic acid metal salts or boric acid metal salts, Lewis acids such as zinc chloride, alkali metal hydroxides such as sulfur and lithium hydroxide, potassium hydroxide, magnesium oxide, calcium hydroxide, etc. Alkaline earth metal oxides or hydroxides, carbonates such as potassium carbonate and sodium bicarbonate, basic phosphorus compounds such as trisu I phosphate and Ryu J phosphate, ammonia, hexamine, quaternary ammonium hydroxide. These include amine compounds such as salts.

These catalysts of the same type may be used alone or in combination of two or more, or an acidic catalyst or a basic catalyst may be used in combination at intervals.

Furthermore, as a modifying agent used to prepare a modified phenolic resin by reacting or mixing it during the production of the phenolic resin, or by mixing it after production, examples include urea, melamine, aniline, guanamine, and the like. Examples include nitrogen compounds, salicylic acid, furfuryl alcohol, cashew nut shell oil, tall oil, lignin, epoxy resin, xylene resin, urea resin, melamine resin, vinyl acetate resin, polyamide resin, and acrylic resin.

In the present invention, the wetting agent used to prevent dust generation from the powdered phenolic resin is desirably one with low compatibility with the resin and low volatility.For example, it is liquid at an environmental temperature of about 35°C, and Preferred are phosphoric acid esters, organic carboxylic acid esters I, oils, or mixtures thereof having a boiling point of C or higher.

Typical specific examples of these wetting agents include tributyl phosphate, tricresyl phosphate, triethyl phosphate,
Phosphate esters such as trisisopropylphenyl phosphate, trioctyl phosphate, octyldiphenyl phosphate,
Butyl stearate, amyl stearate, dioctyl adipate, dioctyl sebacate, dibutyl sebacate, dibutyl maleate, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diheptyl phthalate, dioctyl phthalate, diisodecyl phthalate, phthalic acid Organic carboxylic acid esters such as diallyl and butyrolactone, liquid paraffin, heavy oil, lubricating oil, spindle oil,
Hydrocarbon oils such as turbine oil and machine oil, silicone oils such as polydimethylsiloxane and polyphenylmethylsiloxane, fluorine oils such as trifluorochloroethylene low polymers, linseed oil, olive oil, tung oil, rapeseed oil, Examples include oils such as animal and vegetable oils such as soybean oil, cottonseed oil, camellia oil, coconut oil, castor oil, sesame oil, whale oil, and herring oil.

The amount of the wetting agent blended varies depending on the type of phenolic resin described in NiI, the particle size, the type of wetting agent, the presence or absence of other additives, etc., but is usually based on 100 parts by weight of the phenolic resin. The amount is 5 parts by weight or less, preferably 0.01 to 3 parts by weight.

If this amount exceeds 5 parts by weight, a large amount of surface-treated calcium carbonate is required in order to obtain practical powder flowability, which is not only uneconomical but also reduces the performance as a binder, so this is not preferred. do not have.

As described above, the dry resin felt manufacturing method of the present invention, which uses powdered phenolic resin that has been subjected to dust-proofing treatment to the extent that it maintains powder fluidity that does not cause any practical problems, can reduce work efficiency to a fraction of tU. Since it is possible to prevent the powdery phenolic resin from dissipating, it has the advantage of improving the fixing rate to the fibrous base material, and can be put to practical use.

Furthermore, in relation to the gist of the invention, if desired, the surface-treated calcium carbonate used to improve powder flowability may be treated by treating the surface of the fine particles of calcium carbonate with a resin acid, a resin acid-based surface treatment agent, a fatty acid, or a resin acid-based surface treatment agent. or fatty acid surface treatment agent,
Products treated with surfactants (e.g. cationic, sulfonic acid, sulfuric ester, fatty acid, etc.), lignin, polyacrylic acid surface treatment agents, paraffin surface treatment agents, silicon compounds, or other surface treatment agents. It can be added as a reinforcing filler to synthetic rubber, natural rubber, various synthetic resins, paints, inks, paper, etc. to improve their physical properties (e.g. mechanical properties, electrical properties, thermal properties, etc.) It is widely known by this name in the industry as a material that improves workability and processability, and is actually used in many products.

For example, as calcium carbonate surface-treated with resin acid, Hakuenka 0, Hakuenka DD, Hakureika AA, Hakuenka TDD, Homocal D1 Homocal DM, Llnifant-15 (
Above are product names manufactured by Shiraishi Kogyo Co., Ltd.), MC-7, MT-10
0, MSK-G (the above are product names manufactured by Maruo Calcium Co., Ltd.)
, Bai Rika CC3 Bai Rika CCR1 Bai Rika R as calcium carbonate surface-treated with fatty acid or fatty acid-based surface treatment agent
O6, Gerton 50, Vigot 15, StaVi
got-15A (the above is a product name manufactured by Shiraishi Kogyo Co., Ltd.),
MSK-B,;/J/l/77 Ia200.

MSK-A, MSK-PO, Calfire 100, M
C-T, MC-311, Snow Light SSS, Snow Light SS, M White, M (,7-to s-1 (trade names manufactured by Maruo Calcium Co., Ltd.), Rydon B5-0,
Rydon A (product name manufactured by Bihoku Funka Kogyo Co., Ltd.), Car J
- Surface treated calcium carbonate and Shite Shiraika U
(trade name manufactured by Shiroishi Kogyo Co., Ltd.) Calmos (trade name manufactured by Shiroishi Kogyo Co., Ltd.) as calcium carbonate surface-treated with lignin
, MP-777, PvIP-tooo, MP-Z (
The above is a product name manufactured by Maruo Calcium Co., Ltd.), MSK- as calcium carbonate surface-treated with a silicon-based compound, and FP.
-1 (all product names manufactured by Maruo Calcium Co., Ltd.), 5L-1
01,5L-151, TS Powder 1150 (trade name manufactured by Shiroishi Kogyo Co., Ltd.), MC Coat P-1 (trade name manufactured by Maruo Calcium Co., Ltd.) as carbonic acid-lucium surface treated with paraffin, etc. There is. Among these, those having an average particle size of 1 μm or less are preferable, and it can be said that generally, the smaller the particle size, the greater the effect of improving powder fluidity.

The average particle diameter of the surface-treated calcium carbonate used in the present invention is determined from the specific surface area measured by a constant pressure aeration type specific surface area measuring device using the following formula.

Average particle diameter - Specific surface area x true specific gravity The amount of surface-treated calcium carbonate in the granular phenolic resin composition used in the present invention is based on the type and particle size of the phenolic resin, the type and amount of the wetting agent, and the calcium carbonate. The amount varies depending on the type and particle size of the phenolic resin, the presence or absence of other additives, the desired powder fluidity, etc., but is not necessarily limited, but usually 1 part by weight per 100 parts by weight of the phenolic resin.
It is 5 parts by weight or less, preferably 0.1 to 1O.

Even if the amount of surface-treated calcium carbonate exceeds 15 parts by weight, the effect of improving powder fluidity is small, which is not economical, and also causes a decrease in the function as a binder, which is not preferable.

In addition, the surface-treated calcium carbonate according to the present invention can be used with conventionally commonly used powder fluidity imparting agents, such as higher fatty acid salts such as calcium stearate, higher fatty acid amides such as methylene bisstearamide, polyethylene wax, etc. waxes or AERO3IL
, fine particle silicic acid compounds such as white carbon, talcum powder,
It is also possible to use it in combination with mica powder, etc.

The method for producing the powdered phenolic resin composition used in the present invention is not particularly limited, but for example, first, a wetting agent and a powdered carrier that is substantially incompatible with the wetting agent are thoroughly mixed. A wetting agent-carrier mixture is prepared, and then the mixture and additives such as a mold release agent, or surface-treated calcium carbonate (powder fluidity imparting agent) are added to the solid phenolic resin (base resin). However, it is preferable to pulverize and mix this using a conventional pulverizer.

The powder-like carrier is desirably a fine-grained material such as hexamine powder, thermoplastic resin powder, calcium carbonate powder, fine-grain silicic acid, etc. In particular, hexamine powder used as a hardening agent for resins, or thermoplastic resin. Powder etc. are suitable.

The amount of the carrier other than hexamine is appropriately selected within a range that does not function as a binder, but it is usually 10 parts by weight or less per 100 parts by weight of the phenolic resin.

The powdered phenolic resin composition used in the present invention includes:
In addition to the above-mentioned components, if necessary, any additives commonly used in the past, such as amino silane,
Silane coupling agents such as epoxy silane, fatty acid amides such as ethylene bisstearamide, oxystearamide, stearamide, methylolamide, waxes such as polyethylene wax, paraffin wax, and carnauba wax, calcium stearate, Mold release agents such as stearates such as zinc stearate and magnesium stearate; aromatic carbon Ml such as benzoic acid, salicylic acid, and aminocarboxylic acids; polyhydric phenols such as resorcinol, catechol, bisphenol A1 and bisphenol S; The use of curing accelerators such as alkaline earth metal hydroxides or oxides such as calcium hydroxide, barium hydroxide, and magnesium oxide, and aromatic amines such as aniline, diaminodiphenylmethane, and phenylenediamine will not defeat the purpose of the present invention. It can be blended within the range.

The method for producing dry resin felt is as follows in terms of -FYn. Referring to FIG. 1, natural fibers or synthetic fibers 2 are fed into a hopper feeder (defibrator) 1, the fibers are defibrated, and then dropped into a conveyor 3. A phenolic resin sprayer 5 is applied to the cloak-like fibers 4 being transferred on this drawing N3.
A predetermined amount of powdered phenolic resin 6 is sprayed from the base. The granular phenolic resin is introduced from the storage tank 7 into the resin spreader 5 via a normally flexible transfer vibrator 8 .

The mantle-like fibers 4 on which the powdered phenolic resin 6 has been sprinkled in this way are then supplied to the fleece binding machine 9, where they are further finely defibrated and uniformly mixed with the powdered phenolic resin. The matte fleece 10 drawn out from the fleece manufacturing machine 9 passes through the heating furnace 12 via a conveyor n11. While passing through the heating furnace 12, the phenolic resin in the cloak-like fleece 10 is melted and hardened, thereby bonding the fibers and creating resin felt.

Alternatively, the phenolic resin is pre-cured in the heating furnace 12, and after leaving the heating furnace 12, the felt is heated and pressed in a press to produce a molded resin felt.

In the production of such resin felt, since the powdered felt resin is a fine powder, resins that have not been subjected to conventional dust-proofing treatment are transferred from the storage tank 7 to the spreader 5 via the transfer pipe 8. As mentioned before, when spraying on the mat fibers 4 from the spreader 5,
In addition to scattering as dust and contaminating the working environment, there were problems such as the amount of powdered phenolic resin sprinkled on the mat fibers being inconsistent, resulting in variations in product quality. In addition, during fleece production A9, the powdered phenolic resin flies violently, so the amount of resin in the fleece is not constant, which causes variations in product quality.

Furthermore, in high temperature and high humidity conditions when the powder fluidity of the powdered phenolic resin tends to decrease, the flow of the powdered phenolic resin transferred from the storage tank 7 to the hopper of the resin dispersion N5 through the transfer pipe 8 becomes poor. As a countermeasure against this, a method of applying vibration or shock to storage tanks, transfer pipes, hoppers, etc. using pie breaks or non-cars is generally adopted, but the noise worsens the working environment and also From No. 7, the amount of powdered phenolic resin sprinkled onto the fibers was not constant, resulting in inconveniences such as variations in product quality.

According to the present invention, such inconveniences can be solved by using a powdered phenolic resin that has been dust-proofed, more preferably a powdered phenolic resin that has been dust-proofed and has improved powder flowability. Ru. Note that the dry resin felt manufacturing apparatus shown in FIG. 1 is for illustration only, and it goes without saying that the present invention is not limited thereto.

〔Example〕

Although the present invention will be specifically explained using Examples and Comparative Examples, the technical scope of the present invention is not limited by these Examples. Further, all "parts" and "%" described in Examples and Comparative Examples are based on weight unless otherwise specified.

1 part of lubricating oil (Nippon Oil Co. product M oil) as a moxibustion base soil wetting agent,
100 parts of hexamine was weighed out as a carrier for a wetting agent and a curing agent for the novolac resin, and thoroughly mixed in a mixer to prepare a wetting oil/hexamine mixture.

Next, 1000 parts of flaky novolak resin and 10 parts of calcium stearate as a mold release agent were added to the entire lubricating oil/hexamine mixture, and the mixture was pulverized with an atomizer to obtain a powdered phenolic resin composition (A). This was used as a sample for Example 1 described later. It should be noted that all of the powdered phenolic resins mentioned above and below had a particle size with a 50% cumulative value particle size of about 20 to 25 μm.

9 types of powdered phenolic resin compositions (82) ~
(E) were obtained, and these were used as samples of Examples 2 to 10, respectively.

For comparison and contrast with Reference Examples 1 to 10 above, a conventional powdered phenolic resin composition (F) was obtained according to the method described in Reference Example 1 except that no wetting agent was used. was used as the sample of Comparative Example 1.

1. After weighing out 3 parts of lubricating oil M oil as a wetting agent and 100 parts of hexamine as a carrier for the wetting agent and as a curing agent for the novolac resin, they were thoroughly mixed in a mixer to form a lubricating oil/hexamine mixture. Created.

Next, 1000 parts of flaky novolac resin, 10 parts of calcium stearate as a mold release agent, and 3 parts of surface-treated calcium carbonate (Shiraishi Kogyo Co., Ltd. product Shiroenka 0) as a powder fluidity imparting agent were added to the entire lubricating oil/hexamine mixture. Thereafter, the mixture was pulverized and mixed using an atomizer to obtain a powdered phenol resin composition (G), which was used as a sample of Example 11.

Seven types of powdered phenol resin compositions were prepared in the same manner as in Reference Example 12, except that the various surface-treated Calcilla carbonate 1 shown in Table 1 was used in place of the surface-treated Calcium Carbonate White Gloss 0. Products (■]) to (N) were obtained, and these were used as samples of Examples 12 to 18, respectively.

±Consideration■ 1 process For comparison and contrast with the above Reference Examples 12 to 19, the same procedure as in Reference Example 12 was carried out except that untreated calcium carbonate (Br1lliant 1500, a product of Shiroishi Kogyo Co., Ltd.) was used in place of the surface-treated calcium carbonate Shirasika 0. A powdered phenol resin composition (0) was obtained, which was used as a sample of Comparative Example 2.

Enagisa 1121-23 Three types of powdered phenolic resins were prepared in the same manner as in Reference Example 12, except that the blending amount of lubricating oil M oil and the blending amount of surface treatment calcium carbonate Shiraika O shown in Table 1 were changed. Compositions (Pυ~(P,) were obtained, and these were used as samples of Examples 19 to 21, respectively.

杢3J Yuuse M Lubricating oil 9
types of powdered phenolic resin compositions (Q) to (S) are obtained,
These were used as samples of Examples 22 to 30, respectively.

Daishika 121 "U4 Hungry 2 I" The powdered phenolic resin composition obtained in the reference example was separately added to the recycled fibers obtained by defibrating the fiber Tt base material using a fibrillator, and weighed 100 weight of the fibers. After blending 30 parts by weight with respect to 10 parts by weight, the mixture was sufficiently mixed in a fleece manufacturing machine to produce a cloak-like fleece with a thickness of about 100 nm, and the dust generation during mixing was visually evaluated.

Next, this fleece was sandwiched between wire meshes with a thickness of about 30 m5 and fired for 120 seconds in a hot air heating furnace at an ambient temperature of 130°C to obtain semi-cured felt with a basis weight of 1200 g/rd.

Furthermore, this semi-cured felt was molded at a temperature of 200°C.
After hot-pressing molding under the molding conditions of molding pressure 20 kg / cj and molding time 60 seconds to obtain a molded felt with a thickness of 3 dragons, this was trimmed to obtain a bending strength test piece (length 200 u + width 50 mm), The strength was measured using a universal testing machine. The results of the dust generation and the strength of the molded felt are shown in Table 1.

Further, the identification of calcium carbonate contained in the powdered phenolic resin composition can be carried out by the following analysis method, which is very useful for quality control such as prevention of work errors.

That is, a powdered phenolic resin composition (containing calcium carbonate) is added to a 30% NaBr aqueous solution containing a small amount of surfactant (for example, Libon F), thoroughly shaken and dispersed, and then centrifuged to separate the resin layer (the second layer). 1 layer), NaBr
Separate into aqueous solution (second layer) and precipitate (third layer).

Then, after removing the layers 1 and 2, the remaining precipitate was added with the Na
After adding a Br aqueous solution and repeating the same operation, a precipitate is obtained by washing with water, separating (centrifuge), filtering, and drying.

The presence or absence of surface treatment can be determined by measuring the precipitate obtained by the above pretreatment using an infrared absorption spectrum (IR) and determining the difference spectrum from that of untreated calcium carbonate. Furthermore, after treating the precipitate with an organic solvent such as methanol to extract organic substances, the surface treatment is performed by determining the surface treatment agent by IR method, GPC method, etc., and determining the loss on ignition (900°C x 60 minutes). It is possible to grasp the amount of the agent.

Margin C Effects of the Invention] As is clear from the above explanation, the method of the present invention using a powdered phenolic resin composition that has dustproof properties and has good powder flowability as required. For example, conventionally, storage tanks, hoppers,
Equipment such as transfer pipes, resin spreading machines, and fleece manufacturing machines,
Eliminates the problem of dust generated from equipment, or the noise caused by pie breaks, etc., which are implemented as a countermeasure when resin discharge or clogging problems occur due to decreased powder flowability, especially in high temperature and high humidity conditions. This not only significantly improves the working environment, but also reduces health problems caused by dust adhesion to the human body, providing a comfortable working environment and contributing to further improvements in work efficiency. It is.

In addition, since the resin is spread smoothly by the resin spreader, it is possible to prevent quality variations and decreases in work efficiency due to the problems of spreading that often occur in the past, and prevent resin from scattering, especially in fleece manufacturing machines. Therefore, its practical effects are extremely large, such as improving the resin fixation rate on the fiber base material, improving quality and reducing manufacturing costs.

[Brief explanation of the drawing]

Figure 1 is a schematic diagram showing the manufacturing process of resin felt.
Hopper feeder (defibration machine), 3...conveyor,
4...Fiber, 5...Resin spreader, 6...Powdered phenolic resin, 7...Storage tank, 8...Transfer pipe, 9...Fleece manufacturing machine, 12... heating furnace.

Claims (4)

[Claims] 1. In a method of manufacturing a resin felt by mixing a powdered phenolic resin with a defibrated fibrous base material and then heating and/or heating and pressure molding, a phenolic resin and a wetting agent are essential as the powdered phenolic resin. A method for producing dry resin felt with little dust, characterized by using a powdered phenolic resin composition as a component. 2. The manufacturing method according to claim 1, wherein the wetting agent is at least one liquid compound selected from the group of phosphoric acid esters, organic carboxylic acid esters, and oils having a boiling point of 200° C. or higher. 3. In a method of manufacturing a resin felt by mixing a powdered phenolic resin with a defibrated fibrous base material and then heating and/or heating and pressure molding, the powdered phenolic resin includes a phenolic resin, a wetting agent and A method for producing dry resin felt with little dust, characterized by using a powdered phenolic resin composition containing surface-treated calcium carbonate as an essential component. 4. 4. The manufacturing method according to claim 3, wherein the wetting agent is at least one liquid compound selected from the group of phosphoric acid esters, organic carboxylic acid esters, and oils having a boiling point of 200° C. or higher.