JP2002283313A - Method and apparatus for manufacturing fiberboard - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiberboard capable of manufacturing the fiberboard having excellent adhesive performance by uniformly impregnating a long fiber mat with an adhesive. SOLUTION: The method for manufacturing the fiberboard comprises an impregnating step of impregnating the long fiber mat 1 made of many long fibers 1' selected from the group consisting of at least a kenaf, an oil coconut and a coconut palm, with a water soluble adhesive 3, a drying step of drying the mat 1 obtained in the impregnating step, and a molding step of molding the mat 1 obtained in the drying step to the fiberboard by hot pressing. In this method, an air dry step of drying the mat 1 until a water content of the mat 1 becomes 100% or less by supplying air 3 to the mat 1 obtained in the impregnating step is employed as the drying step. Thus, the mat 1 can be dried uniformly to its interior. The mat 1 can be dried while imparting a force of a reverse direction to the direction for moving the moisture and the adhesive component to the surface of the mat at the drying time by supplying the air 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to kenaf, oil palm,
The present invention relates to a method for producing a fiberboard using a long fiber obtained from any of coconut palms as a raw material and an apparatus for producing the same.

[0002]

2. Description of the Related Art Wood-based boards such as plywood, particle board, and MDF (medium fiber board) are used for building members such as flooring, wall and ceiling materials, door members, and building members such as skirting boards and surrounding edges. Used in a wide range of fields such as furniture materials.

[0003] These wood-based boards are formed into a plate shape by bonding a veneer, a piece of wood (particles), and a wood fiber, which are mainly obtained by processing softwood or hardwood. Therefore, it has characteristics such as stable quality, less anisotropy and excellent workability, as compared with a ground plate obtained by sawing raw wood.

On the other hand, due to global environmental problems in recent years, regulations on deforestation have been strengthened for the purpose of protecting the forest. There has been a growing demand for

In response to such demands, the development of boards using non-wood resources has been promoted, and non-wood lignocellulose such as bagasse, kolyan, oil palm (oil palm), jute, bamboo, etc. is used as a board material. Resources are starting to attract attention.

[0006] Regarding such boards utilizing non-wood resources, the present inventors have already disclosed in Japanese Patent Application Laid-Open No. H11-333886.
In the official gazette, kenaf (annual herbaceous mallow),
By using long fibers obtained from either oil palm or coconut as a raw material and orienting the long fibers in one direction or orthogonal direction, it is lightweight, high strength, and excellent in dimensional stability in the length direction. Is disclosed.

[0007] In the above-mentioned fiberboard, the bonding performance and the quality performance are mutually related, and a fiberboard having a sufficient bonding performance between fibers can be obtained with high strength and high performance. Are known. Therefore, in order to impart excellent performance to the fiberboard, it was essential to improve the adhesive performance. That is, it was necessary to uniformly apply an adhesive to a long fiber mat made of a long fiber aggregate having fiber directionality. Therefore, while higher performance and lower cost are required, it is essential to establish a method of manufacturing a fiberboard for uniformly applying an adhesive to a long fiber mat.

[0008] As a method of manufacturing a fiberboard for adhering an adhesive to a long fiber mat, there are generally a method of spraying an adhesive using a spray or the like, and a method of manufacturing a long fiber mat in a tank containing the adhesive. The latter method is used as an effective method because the latter method allows the adhesive to adhere more uniformly and has no problem such as scattering of the adhesive. Here, a water-soluble adhesive (water-soluble adhesive) is mainly used as the adhesive used in the above method. This is because it is possible to manufacture with a simpler facility as compared with the case where a flammable dangerous substance such as an organic solvent is used, and the solid content ratio of the adhesive can be easily controlled by dilution or the like. is there.

As a specific manufacturing process using such a water-soluble adhesive, first, as shown in FIG. 9A, at least one of kenaf, oil palm and coconut is used. A long fiber mat 1 comprising a large number of long fibers 1 'obtained from a leather portion is immersed in an impregnation tank 7 and an adhesive 2
Impregnation step of impregnating and attaching
As shown in (b), the long fiber mat 1 obtained by the impregnation step is dried in a heating and drying device 30 such as a drier to remove excess water, and finally, a drying step is performed.
As shown in (c), after a predetermined amount of the long fiber mat 1 obtained in the drying step is laminated, it is sandwiched between a pair of press plates 22 of a hot-press device 21 and heated and pressed to form a fiber plate. The process is performed.

[0010]

However, the above-described manufacturing method and manufacturing process have the following problems. That is, in the drying step, FIG.
As shown in FIG. 10A, the long fiber mat 1 is dried in a heating / drying device 30 such as a drier by supplying heat 3 ', and as shown in FIG. The water 2a moves to the surface of the long fiber mat 1 and evaporates. At this time, the adhesive component (adhesive 2
The solid component 2b also moves to the surface of the long fiber mat 1 similarly to the moisture 2a, and therefore, in the long fiber mat 1 after drying, as shown in FIG. Becomes uneven in the thickness direction of
Therefore, there is a possibility that the adhesive performance of the fiberboard is reduced and the quality performance is deteriorated. In addition, since the drying time is relatively long, it is necessary to introduce large-scale drying equipment in order to efficiently manufacture the fiberboard, and at the same time, the energy consumed for drying is enormous. There was a fear of being connected.

The present invention has been made in view of the above points, and a fiber board having excellent adhesive performance can be manufactured by uniformly impregnating an adhesive into a long fiber mat, and the manufacturing efficiency can be improved. It is an object of the present invention to provide a fiberboard manufacturing method and a fiberboard manufacturing apparatus which can easily cope with continuous productivity.

[0012]

According to a first aspect of the present invention, there is provided a method for manufacturing a fiberboard, comprising a long fiber mat comprising a plurality of long fibers obtained from at least one of kenaf, oil palm and coconut. An impregnating step of impregnating a water-soluble adhesive 2 with a water-soluble adhesive 2, a drying step of drying the long fiber mat 1 obtained in the impregnation step, and forming the long fiber mat 1 obtained in the drying step into a fiberboard by hot pressing. In the method for producing a fiberboard comprising a molding step, an air-drying step of supplying air 3 to the long fiber mat 1 obtained in the impregnation step and drying until the water content becomes 100% or less is used as the drying step. It is assumed that. By using the air drying step, it is possible to uniformly dry the inside of the long fiber mat 1 and to apply a force in a direction opposite to the direction in which the moisture 2a and the adhesive component 2b move to the surface of the long fiber mat 1 during drying. The long fiber mat 1 can be dried while being supplied to the long fiber mat 1 by the supply of the air 3, and the long fiber mat 1 can be uniformly dried while suppressing the movement of the adhesive component 2 b uniformly adhered to the long fiber mat 1 by the impregnation process. Thus, it is possible to easily produce a fiber board having excellent adhesion performance.

[0013] According to a second aspect of the present invention, in addition to the first aspect, the drying step comprises supplying the room temperature air 3 to the long fiber mat 1 obtained in the impregnation step. A normal temperature air drying step of drying until the water content becomes 100% or less, and a warm air drying step of supplying air 4 of 40 ° C. or more to the long fiber mat 1 obtained in the normal temperature air drying step and drying. It is characterized by the following. By using the room temperature air drying step, it is easier to dry the long fiber mat 1 while suppressing the movement of the adhesive component 2b uniformly adhered to the long fiber mat 1 by the impregnation step, and the fiber having excellent adhesion performance is obtained. The plate can be manufactured more easily, and the drying efficiency can be effectively increased by using the hot air drying step.

[0014] According to a third aspect of the present invention, in addition to the structure of the first or second aspect, the air drying step further comprises the step of:
A weak air drying step in which air 5 having a wind speed of 5 m / s or less is supplied to the long fiber mat 1 obtained in the impregnation step to dry the same, and a long fiber mat 1 obtained in the weak air drying step has a wind velocity of 10 m / s or more. It is characterized by comprising a strong wind drying step of supplying air 6 and drying. By using the weak air drying step, the long fiber mat 1 is dried without causing the movement of the adhesive component 2b uniformly attached to the long fiber mat 1 by the impregnation step while minimizing the load on the long fiber mat 1. The drying efficiency can be effectively increased by using the strong air drying step.

According to a fourth aspect of the present invention, in addition to any one of the first to third aspects, the air drying step uses dry air having a relative humidity of 60% or less in the air drying step. It is assumed that. By using such dry air, it is possible to more effectively increase the drying efficiency in addition to the effects described above.

According to a fifth aspect of the present invention, in addition to any one of the first to fourth aspects, in the impregnating step, the solid content ratio of the adhesive 2 is 10 to 50%.
It is characterized by adjusting to. By adjusting the solid content ratio of the adhesive 2 to this range, the adhesive component 2
b can be effectively dispersed in the adhesive 2, and the amount of the adhesive can be reduced.

A method of manufacturing a fiberboard according to a sixth aspect of the present invention is characterized in that, in addition to any one of the first to fifth aspects, a water-soluble phenol adhesive is used as the adhesive 2. is there. By using the water-soluble phenol adhesive, the adhesive component 2b becomes extremely stable in the aqueous solution at the time of dilution, so that the uniform adhesion to the long fiber mat 1 during the impregnation step is further improved,
It is possible to easily produce a fiberboard having even better adhesion performance.

A method of manufacturing a fiberboard according to a seventh aspect of the present invention is characterized in that, in addition to any one of the first to sixth aspects, the viscosity of the adhesive 2 is adjusted to 10 to 300 mPa · s. Things. By adjusting the viscosity of the adhesive 2 to this range, the movement of the adhesive component 2b at the time of drying becomes less likely to occur, so that the movement of the adhesive component 2b uniformly attached to the long fiber mat 1 by the impregnation step is further suppressed. In this state, the long fiber mat 1 can be dried, and a fiber board having excellent adhesion performance can be manufactured more easily.

The method for manufacturing a fiberboard according to the eighth aspect of the present invention is the same as the first to seventh aspects, except that in the impregnation step, the long fiber mat 1 is reduced in thickness by being sandwiched between rollers 8 or the like. It is characterized by impregnating with an adhesive 2. By impregnating the adhesive 2 into the long fiber mat 1 in such a state, the adhesive 2 is effectively impregnated into the long fiber mat 1 in a state where bubbles remaining between the long fibers 1 ′ are eliminated. This makes it possible to further improve the uniform adhesion to the long fiber mat 1 of the adhesive component 2b during the impregnation step, and to easily produce a fiber board having more excellent adhesive performance.

According to a ninth aspect of the present invention, there is provided a method of manufacturing a fiberboard according to any one of the first to eighth aspects, wherein an adhesive is applied to the long fiber mat 1 adjusted to have a thickness of 3 to 20 mm. 2 is impregnated. By impregnating the adhesive 2 into the long fiber mat 1 whose thickness has been adjusted to the above range, the moving distance of the adhesive component 2b in the thickness direction of the long fiber mat 1 during drying can be reduced. The long fiber mat 1 can be dried in a state in which the movement of the adhesive component 2b uniformly attached to the mat 1 is further suppressed, and a fiber board having excellent adhesive performance can be manufactured more easily.

According to a tenth aspect of the present invention, in addition to any one of the first to ninth aspects, the method for manufacturing a fiberboard according to the present invention provides a long fiber mat 1 adjusted to have a mat moisture content of 5% or less. It is characterized by impregnating with an adhesive 2. By impregnating the adhesive 2 into the long fiber mat 1 adjusted so that the moisture content of the mat is in the above range, a part of the adhesive component 2b can be made to penetrate near the surface of the long fiber 1 during the impregnation step. It is possible to dry the long fiber mat 1 in a state where the movement of the adhesive component 2b uniformly attached to the long fiber mat 1 by the process is further suppressed, and it is possible to more easily manufacture a fiber board having excellent adhesion performance. Become.

According to a fifteenth aspect of the present invention, there is provided a method for manufacturing a fiberboard according to any one of the first to tenth aspects, wherein an adhesive is applied to a long-fiber mat adjusted to have a porosity of 90% or more. Is impregnated. By impregnating the adhesive 2 into the long fiber mat 1 adjusted so that the porosity is within the above range, the moving path of the adhesive component 2b in the thickness direction of the long fiber mat 1 can be reduced at the time of drying. Long fiber mat 1 depending on the process
The long fiber mat 1 can be dried in a state in which the movement of the adhesive component 2b uniformly adhered to the fiber is further suppressed, and a fiber board having excellent adhesive performance can be manufactured more easily.

A fiberboard manufacturing apparatus according to a twelfth aspect of the present invention provides an impregnation mechanism 31 for impregnating a long-fiber mat 1 with a water-soluble adhesive 2 and supplying air 3 to the long-fiber mat 1. A drying mechanism 32 having an air drying function for drying;
And a forming mechanism 33 for forming the fiberboard by heat and pressure. By adopting such a configuration, the fiber which can dry the long fiber mat 1 uniformly while suppressing the movement of the adhesive component 2b uniformly adhered to the long fiber mat 1 by the impregnation step, and has excellent adhesive performance The plate can be easily manufactured, and can be used as a manufacturing apparatus that can easily cope with continuous production.

According to a thirteenth aspect of the present invention, in addition to the structure of the twelfth aspect, there is provided a room temperature air drying function for supplying the room temperature air 3 to the long fiber mat 1 for drying, and a long fiber mat. 1 is provided with a drying mechanism 32 having a hot air drying function of supplying air of 40 ° C. or more to dry. With such a configuration,
After drying the long fiber mat 1 without causing the movement of the adhesive component 2b uniformly adhered to the long fiber mat 1 by the impregnation step, the long fiber mat 1 can be further dried efficiently, and during the molding step In this case, the molding time can be shortened, and a fiber board having excellent adhesion performance can be manufactured more easily.

According to a fifteenth aspect of the present invention, in addition to the structure of the twelfth or thirteenth aspect, the weak wind for supplying the air 5 having a wind speed of 5 m / s or less to the long fiber mat 1 and drying the same is provided. It is characterized by having an air drying mechanism 34 having an air drying function and a strong air drying function for supplying the air 6 having a wind speed of 10 m / s or more to the long fiber mat 1 and drying it. With such a configuration, the long fiber mat 1 can be dried without causing the movement of the adhesive component uniformly attached to the long fiber mat 1 by the impregnation step, and
The drying efficiency can be effectively increased.

[0026]

Embodiments of the present invention will be described below.

The long fiber mat 1 used in the present invention comprises a large number of long fibers 1 'obtained from kenaf, oil palm, and coconut palm.
Kenaf, oil palm, coconut palm may be used to form the long fiber mat 1 from one kind of long fiber 1 ′, or kenaf, oil palm,
The long fiber mat 1 may be formed by using two or more kinds of long fiber aggregates selected from coconut. The method of forming the long fiber mat 1 is not particularly limited. For example, a method of cutting an aggregate of the long fibers 1 ′ in the length direction and stacking a plurality of them to form a mat, or a method of collecting the long fibers 1 ′ Examples of the method include laminating the bodies and forming a mat using a device such as a cross layer or a needle punch.

The adhesive 2 used in the present invention is not particularly limited as long as it is a water-soluble adhesive in which all or most of the solvent is water. For example, the adhesive 2 contains a urea resin as an adhesive component (solid content) 2b. A water-soluble urea resin adhesive, a water-soluble melamine resin adhesive containing a melamine resin as the adhesive component 2b, a water-soluble vinyl acetate adhesive containing a vinyl acetate resin as the adhesive component 2b, and a water-soluble resin containing a phenol resin as the adhesive component 2b A phenolic resin adhesive or the like can be used. Among them, it is preferable to use a water-soluble phenol resin adhesive. Since the water-soluble phenol resin adhesive has a particularly high affinity for water among the water-soluble adhesives, it has a feature that the adhesive component 2b is extremely stably present in the adhesive 2 even when diluted with water. . Therefore, even when the solid content ratio of the adhesive 2 is adjusted by dilution, the uniform adhesion to the long fiber mat 1 of the adhesive component 2b during the impregnation step is improved as compared with using another adhesive. This makes it possible to easily produce a fiberboard having even better adhesive performance than using the above adhesive.

FIG. 1 is a schematic view showing an example of an embodiment of the manufacturing method of the present invention. In this embodiment, an air drying step is used as the drying step. That is, the long fiber mat 1 is first immersed in the adhesive 2 stored in the impregnation tank 7 to impregnate the adhesive 2 into the long fiber mat 1 in the impregnation step shown in FIG. Next, FIG.
In the air drying step (drying step) shown in (b), air 3 is blown and supplied to the long fiber mat 1 obtained in the impregnation step to remove water 2a until the water content of the long fiber mat 1 becomes 100% or less. And dry. Here, the moisture content of the long fiber mat 1 is the ratio of the weight of water in the long fiber mat 1 to the weight of the fibers of the long fiber mat 1. Next, as shown in FIG. 1 (c), the dried long fiber mat 1 obtained in the air drying step is put into a pair of press plates 2 of a hot-press device (hot press) 21.
2, the long fiber mat 1 is sandwiched between the press plates 22 and hot-pressed (heat-pressed) to further dry the long fiber mat 1 and the adhesive 2 impregnated in the long fiber mat 1. By curing the adhesive component 2b, a fiberboard can be formed.

FIGS. 2 (a) to 2 (c) show a mechanism for drying the water 2a by the air drying step of the present invention, and FIGS. The drying mechanism of the water 2a when dried in the heating and drying device 30 is shown. 2 (a) to 2 (c) are compared with FIGS. 2 (d) to 2 (f). In the case of FIGS. 2 (d) to 2 (f), as shown in FIG. As shown in FIG. 2 (e), the evaporation of the water 2a due to the drying step mainly occurs on the surface of the long fiber mat 1 and the water 2a on the surface of the long fiber mat 1 With the evaporation, the moisture 2a 'remaining inside the long fiber mat 1 moves to the surface of the long fiber mat 1. At this time, the adhesive component 2b 'adhered to the long fiber 1' by uniformly impregnating the inside of the long fiber mat 1 in the impregnating step also contains water 2
Since the adhesive component 2b moves to the vicinity of the surface of the long fiber mat 1 at the same time as a ′, the adhesive component 2b after drying is mainly concentrated near the surface of the long fiber mat 1 as shown in FIG. 1 becomes uneven in the thickness direction. Accordingly, when the long fiber mat 1 dried under such conditions is formed into a fiberboard, the adhesive performance (particularly between the long fibers 1 ′) of the inside of the long fiber mat 1 where the adhesive component 2 b is less adhered is particularly high. Adhesive strength).

On the other hand, in the case of FIGS. 2 (a) to 2 (c),
Since the air 3 is supplied to the long fiber mat 1 from the surface side toward the inside as shown in FIG. 2 (a), the air 3 permeates into the long fiber mat 1 and the entire long fiber mat 1 is effective. Can be dried. Further, the supply of the air 3 makes it possible to apply a force in a direction opposite to the direction in which the moisture 2a 'and the adhesive component 2b' inside the long fiber mat 1 move to the surface of the long fiber mat 1 during drying. By the above operation, it is possible to dry the adhesive component 2b 'while suppressing the movement phenomenon of the adhesive component 2b' as seen in the cases of FIGS. 2 (d) to 2 (f).

The present inventors have made various studies based on the above theory. As a result, if the long fiber mat 1 is dried by the air drying process until the moisture content of the long fiber mat 1 becomes 100% or less, the moisture inside the long fiber mat 1 is reduced. It has been found that the migration of the long fiber mat 1 to the surface of the long fiber mat 1 does not occur.

Here, in the present embodiment, the conditions of the supplied air 3 (ie, temperature, relative humidity, wind speed, etc.)
Are the physical properties (ie, density,
The temperature of the air 3 can be set to a normal temperature (about 25 ° C.), for example.

FIG. 3 is a schematic view showing an example of another embodiment of the manufacturing method of the present invention. In this embodiment, as a drying step, the long fiber mat 1 obtained in the impregnation step is blown and supplied with air 3 at room temperature to remove water 2a until the moisture content of the long fiber mat 1 becomes 100% or less, and then drying. Room temperature air drying step and the long fiber mat 1 obtained in the room temperature air drying step
And a hot-air drying step of blowing and supplying air 4 of 40 ° C. or more to the air and drying. The impregnation step and the molding step are the same as in the above embodiment.

As one of the methods for increasing the drying efficiency in the air drying step, a method of supplying hot air and drying is conceivable. In this method, it is necessary for the hot air to penetrate into the long fiber mat 1. Evaporated water 2a (mainly near the surface)
Since the heat of vaporization is deprived of heat, a slight temperature distribution occurs in the thickness direction of the long fiber mat 1 depending on the thickness and density of the long fiber mat 1 to be used. And wind speed) need to be controlled more precisely. On the other hand, since the temperature distribution in the thickness direction inside the long fiber mat 1 during drying can be kept as uniform as possible by using the normal temperature air 3, the long fiber mat 1 is uniformly impregnated in the impregnation step. This makes it easier to dry the long fiber mat 1 while suppressing the movement of the adhesive component 2b adhered thereto.

In the molding step, it is necessary to apply sufficient heat and pressure to the long fiber mat 1 to evaporate the water 2a of the long fiber mat 1 and to cure the adhesive component 2b of the adhesive 2. According to the present embodiment, first, the long fiber mat 1 is dried in a room temperature air drying step until the moisture content of the long fiber mat 1 becomes 100% or less, and the moisture 2a 'inside the long fiber mat 1 is dried.
In order to prevent the adhesive component 2b 'from moving to the surface of the long fiber mat 1 and to further dry it in the warm air drying step, the time for evaporating the water 2a in the molding step, that is, the molding time is effectively reduced. Can be reduced to Therefore, it is possible to more easily produce a fiber board having excellent adhesion performance.

The air 4 used in the hot air drying step
The temperature range of (warm air) is 40 ° C. or more. If the temperature is lower than this, the evaporation of the water 2a from the long fiber mat 1 becomes slow, and a long time is required for the hot air drying step, so that there is a possibility that the fiber board cannot be manufactured efficiently. The upper limit of the temperature of the air 4 used in the hot air drying step is not particularly limited, but is preferably controlled to be equal to or lower than the curing temperature of the adhesive component 2b of the adhesive 2, and is appropriately adjusted according to the physical properties of the adhesive 2 to be used. Selected. Therefore, generally, the temperature of the air 4 is 12
The temperature may be set to about 0 ° C., but is not limited thereto.

FIG. 4 is a schematic view showing an example of another embodiment of the manufacturing method of the present invention. In this embodiment, an air drying step is used as a drying step. The air drying step is a weak air drying step in which air 5 having an air velocity of 5 m / s or less is blown onto the long fiber mat 1 obtained in the impregnation step to supply and dry. And a wind speed of 10 m / s to the long fiber mat 1 obtained in the weak air drying step.
A strong air drying step in which the air 6 is blown to supply and dry is performed. The air drying step is performed until the moisture content of the long fiber mat 1 becomes 100% or less. The impregnation step and the molding step are the same as in the above embodiment.

The long fiber mat 1 immediately after the impregnation step has a moisture 2a
And, since it contains a large amount of the adhesive component 2b, the weight is usually increased to about 150 to 400% as compared with before the impregnation step. When air is supplied in this state, if the air velocity is too high with respect to the increase in weight of the long fiber mat 1, the long fiber mat 1 may be deformed due to a load. Therefore, by using a weak air drying process, the long fiber mat 1
The long fiber mat 1 is dried without causing the movement of the adhesive component 2b uniformly adhered to the long fiber mat 1 by the impregnation process while minimizing the load on the long fiber mat 1, and the drying proceeds to some extent to deform the long fiber mat 1. The drying efficiency can be effectively increased by using the strong air drying step after the state in which drying does not occur.

The wind speed in the weak air drying step is 5 m /
s or less, whereby the long fiber mat 1
Can be prevented from increasing. Further, it is preferable that the wind speed in the weak air drying step is 1 m / s or more. If the wind speed is lower than this, the drying efficiency becomes low and it takes too much time. The wind speed in the strong wind air drying step is set to 10 m / s or more, whereby the drying efficiency does not decrease and the drying does not take a long time. The upper limit of the wind speed in the strong wind air drying step is not particularly limited, and there is no problem as long as the wind speed does not break the long fiber mat 1.

In the embodiment shown in FIG. 4, the above-mentioned hot air drying step can be performed after the strong air drying step. In the present embodiment, the supply air 5, 6
Conditions other than the wind speed (ie, temperature, relative humidity, etc.)
The temperature of the air 5 and 6 can be set to a normal temperature (about 25 ° C.), for example, as appropriate, depending on the physical properties (that is, the density, the thickness, etc.) of the long fiber mat 1 to be used.

In any of the above embodiments, dry air having a relative humidity of 60% or less is used as the air 3 to 6 used in the air drying step (including the normal temperature air drying step, the weak air drying step, and the strong air drying step). preferable. By using such dry air, it is possible to more effectively increase the drying efficiency in addition to the effects described above.
The lower limit of the relative humidity of the dry air used in the present invention is 0%.

Further, in any of the above embodiments, the solid content ratio of the adhesive 2 (adhesive 2
Is preferably adjusted to 1 to 50% by weight in terms of the solid content (content ratio of the adhesive component 2b) with respect to the total amount of Adhesive 2
By adjusting the solid content ratio in this range, the adhesive component 2b can be effectively reduced because the adhesive component 2b is effectively dispersed in the liquid of the adhesive 2, and as a result, less adhesive The amount of the agent 2 makes it possible to easily produce a fiberboard having a sufficient adhesive property.

The method of adjusting the solid content ratio of the adhesive 2 is not particularly limited, and examples thereof include a method of controlling a dilution ratio with water or the like and a method of removing a solvent from the adhesive 2 by evaporation or the like. be able to.

In each of the above embodiments, the viscosity of the adhesive 2 used in the impregnation step is set to 10 to 300 m.
It is preferably adjusted to Pa · s (at 25 ° C.).
By adjusting the viscosity of the adhesive 2 to fall within this range, the viscosity of the adhesive 2 can be increased as the moisture 2a evaporates in the air-drying step while maintaining uniform adhesion to the long fiber mat 1 in the impregnation step. By increasing, the movement of the adhesive component 2b at the time of drying becomes less likely to occur, and therefore, the adhesive component 2b uniformly adhered to the long fiber mat 1 by the impregnation step.
The long fiber mat 1 can be dried in a state in which the movement of the fiber is further suppressed, and it becomes possible to more easily produce a fiber board having excellent adhesion performance.

The method for adjusting the viscosity of the adhesive 2 is not particularly limited. For example, a method for controlling the dilution ratio with water or the like, or a method for adjusting the viscosity by using a thickener such as flour or methyl cellulose as appropriate. And the like.

Further, in any of the above-described embodiments, the long fiber mat 1 is
It is preferable to perform the impregnation step while sandwiching. That is,
As shown in FIG. 5A, the impregnation tank 7 used in the impregnation step is used.
And a pair of upper and lower rollers 8 is installed in a state immersed in the adhesive 2 so that the long fiber mat 1 is impregnated with the adhesive 2 while being sandwiched between the rollers 8 from above and below during the impregnation step. . By performing the impregnation step in this manner, as shown in FIG. 5B, the long fiber mat 1 is compressed in the thickness direction by the pressure of the roller 8 to be thin, and the air bubbles 9 in the long fiber mat 1 are reduced. Is removed by squeezing the roller 8, and since the long fiber mat 1 is restored after passing through the roller 8, the adhesive 2 is efficiently impregnated into the inside of the long fiber mat 1. . Accordingly, the adhesiveness of the adhesive 2 to the long fiber mat 1 in the impregnation step is further improved, and it is possible to easily manufacture a fiber board having more excellent adhesive performance.

In any of the above embodiments, it is preferable that the long fiber mat 1 adjusted to have a thickness of 3 to 20 mm is impregnated with the adhesive 2. By impregnating the adhesive 2 into the long fiber mat 1 whose thickness has been adjusted to this range, the moving distance of the adhesive component 2b in the thickness direction of the long fiber mat 1 during drying can be reduced. Therefore, the long fiber mat 1 can be dried in a state in which the movement of the adhesive component 2b uniformly attached to the long fiber mat 1 by the impregnation step is further suppressed, and the fiber board excellent in the adhesion performance can be more easily manufactured. Is possible.

The thickness of the long fiber mat 1 can be adjusted by any method such as pressurizing with a press or adjusting the amount of the long fiber 1 'used.

In any of the above embodiments, it is preferable that the long fiber mat 1 adjusted to have a moisture content of 5% or less is impregnated with the adhesive 2. By impregnating the adhesive 2 into the long-fiber mat 1 adjusted so that the water content of the mat is in this range, a part of the adhesive component 2b permeates near the surface of the long fiber 1 during the impregnation step. When the air drying process is performed in
The adhesive component 2b that has penetrated near the surface of the long fiber mat 1 becomes difficult to move to the surface of the long fiber mat 1 even when the water 2a evaporates. Therefore, the long fiber mat 1 can be dried in a state in which the movement of the adhesive component 2b uniformly attached to the long fiber mat 1 by the impregnation step is further suppressed, and a fiber board having excellent adhesion performance can be more easily manufactured. Is possible.

The moisture content of the mat is the moisture content of the long fiber mat 1 before the impregnation step, and is the ratio of the weight of the water in the long fiber mat 1 to the weight of the fibers of the long fiber mat 1. The lower limit of the moisture content of the long fiber mat 1 used in the present invention is not particularly limited, and is 0%. Further, as a method for adjusting the moisture content of the mat, an arbitrary method such as drying with a dryer or the like can be used.

In any of the above embodiments, it is preferable to impregnate an adhesive into a long fiber mat adjusted to have a porosity of 90% or more. When the porosity of the long fiber mat 1 is increased to about this range, the number of long fibers 1 ′ constituting the long fiber mat 1 decreases. Therefore, it is possible to reduce the contact portion between the long fibers 1 ′, which serves as a movement path of the adhesive component 2 b in the thickness direction of the long fiber mat 1 during drying, and the adhesive component 2 b uniformly adhered to the long fiber mat 1 by the impregnation process. The long fiber mat 1 can be dried in a state in which the movement of the fiber is further suppressed, and a fiber board having excellent adhesive performance can be manufactured more easily.

In consideration of the strength of the long fiber mat 1, the upper limit of the porosity in practical use is preferably set to 99.5%. The porosity of the long fiber mat 1 is
Can be calculated from the volume, weight, and specific gravity of the long fiber 1 '. Furthermore, the porosity of the long fiber mat 1 can be adjusted by changing the amount of the long fibers 1 'and the density of the long fibers 1' with a small number of operations (for example, needle punching) for entanglement of the long fibers 1 '. You can do it.

In each of the above embodiments,
The moisture content of the long fiber mat 1 after this impregnation step is determined by the adhesive 2
It is preferably about 150 to 200% in consideration of easiness of impregnation. In any of the above embodiments, the moisture content of the long fiber mat 1 after the air drying step is preferably 20% or more, but is not limited thereto. However, trying to lower the water content to less than 20% is time-consuming, time-consuming and inefficient. Furthermore, in any of the above embodiments, the moisture content of the long fiber mat 1 after the drying step is preferably set to 10 to 30%, and if it is higher than this, the appearance of the obtained fiber board is deteriorated (stained state). ).

FIG. 6 is a schematic view showing an example of an embodiment of the manufacturing apparatus of the present invention. This embodiment is a manufacturing apparatus for carrying out the embodiment shown in FIG. 1, and an impregnation mechanism for impregnating a long fiber mat 1 with a water-soluble adhesive 2 as shown in FIG. 31, a drying mechanism 32 having an air drying function for supplying air 3 to the long fiber mat 1 for drying as shown in FIG. 6 (b), and a fiber by hot pressure as shown in FIG. 6 (c). And a forming mechanism 33 for forming into a plate.

The impregnating mechanism 31 includes an impregnating tank 7 that fills and stores the adhesive 2, a plurality of transport rollers 11 attached to the impregnating tank 7, and a squeeze roller 12 that is disposed on the outlet side of the impregnating tank 7. Is formed. The impregnation tank 7 is formed with an open upper surface, and has one end as an inlet side and the other end as an outlet side. The transport rollers 11 are vertically opposed to form a pair, and two transport rollers 11 are attached to the upper part of the impregnation tank 7. A part of the transport roller 11 is immersed in the adhesive 2 in the impregnation tank 7. Squeezing roller 1
Numeral 2 is formed by two opposing top and bottom.

The drying mechanism 32 is provided with a transport roller 35 for transporting the long fiber mat 1 obtained in the impregnation step, and an air drying mechanism 34 including a fan such as a fan 13. The air drying mechanism 34 has an air drying function. The transport roller 35 is an air drying mechanism 34
And a plurality of the long fiber mats 1 are arranged in a direction parallel to the conveying direction of the long fiber mat 1. Air drying mechanism 3
4 is provided above the transport roller 35,
Two air drying mechanisms 34 are arranged in a direction parallel to the transport direction of the long fiber mat 1.

The forming mechanism 33 is for laminating a predetermined number of the long fiber mats 1 obtained in the drying step by the drying mechanism 32 (the air drying mechanism 34) and hot-pressing as a fiber board.
It is formed by a hot-press device (hot press) 21 having a pair of upper and lower press plates 22.

The manufacture of a fiberboard using such a fiberboard manufacturing apparatus is performed as follows. First, the long fiber mat 1 is vertically sandwiched by the transport rollers 11 and advances from the inlet side to the outlet side of the impregnation tank 7, and the long fiber mat 1 is sandwiched by the transport rollers 11.
Is immersed in the adhesive 2 of the impregnation tank 7, and then the excess adhesive 2 is squeezed out by the squeeze roller 12 with the long fiber mat 1 pulled up from the adhesive 2. I do. Excess adhesive 2 squeezed out of the long fiber mat 1 falls into the impregnation tank 7 and is returned and reused.

Next, the long fiber mat 1 which has been subjected to the impregnation step is conveyed to the drying mechanism 32 (air drying mechanism 34). Here, the long fiber mat 1 is conveyed by the conveying rollers 35 to the long fiber mat 1 from above. The drying process is performed by the drying mechanism 32 by blowing and supplying air 3 (room temperature air 3) to remove and dry the water 2a until the moisture content of the long fiber mat 1 becomes 100% or less. At this time, by a method such as measuring the weight change of the long fiber mat 1 before and after the drying step,
Can be dried until the water content is less than 100%,
Thereby, it becomes possible to easily manufacture a fiber board having excellent adhesion performance. Further, unlike the batch type heating and drying apparatus 30 as shown in FIG. 9, the long continuous fiber mat 1 can be dried while being conveyed by a conveyor such as a transport roller 35, and can be easily adapted to continuous production. It is possible to do.

Next, the dried long fiber mat 1 is placed between a pair of press plates 22 of the hot-press device 21, and the long fiber mat 1 is sandwiched between the press plates 22 and hot-pressed (heat-pressed). Thus, the molding process is performed by the molding mechanism 33 by further drying the long fiber mat 1 and curing the adhesive component 2b of the adhesive 2 impregnated in the long fiber mat 1. Thus, a fiberboard can be formed.

The operating conditions (namely, the feed speed of the long fiber mat 1 by the transport roller 11 and the transport roller 35, the immersion time of the long fiber mat 1 in the adhesive 2, the clearance of the squeeze roller 12, the air drying) The wind speed and air drying time of the air 3 generated by the mechanism 34, as well as the molding temperature, molding pressure, molding time, etc. in the molding process)
Required fiberboard physical properties (ie, fiberboard density,
Thickness, fat content, etc.).

FIG. 7 is a schematic view showing an example of another embodiment of the manufacturing apparatus of the present invention. This embodiment is a manufacturing apparatus for implementing the embodiment shown in FIG. 3, and is different from the apparatus shown in FIG. The impregnation mechanism 31 shown in FIG. 7A and the forming mechanism 33 shown in FIG. 7C are the same as those shown in FIGS. 6A and 6C, respectively.

As shown in FIG. 7B, the drying mechanism 32 includes a transport roller 35 for transporting the long fiber mat 1 obtained in the impregnation step, and a room temperature air drying mechanism including a fan such as a fan 13. 36, and a warm air drying mechanism 37 provided with a heater 14 immediately above a transport roller 35 immediately below a blower such as a fan 13, and a normal temperature air drying mechanism and a warm air drying mechanism by a normal temperature air drying mechanism 36. The drying mechanism 32 is provided with a hot air drying function by 37. A plurality of transport rollers 35 are provided below the normal temperature air drying mechanism 36 and the hot air drying mechanism 37, and are arranged in a direction parallel to the transport direction of the long fiber mat 1. Further, the room temperature air drying mechanism 36 and the warm air drying mechanism 37 are disposed above the transport roller 35, and the room temperature air drying mechanism 36 and the warm air drying mechanism 37 are arranged in a direction parallel to the conveyance direction of the long fiber mat 1. ing. The room temperature air drying mechanism 36 supplies room temperature air 3 to the long fiber mat 1 after the impregnation step, and the warm air drying mechanism 37 supplies the long fiber mat 1 after the room temperature air drying step to the air 4 (40 ° C. or higher). ). The air 4 is heated by the heater 14. The hot air drying mechanism 37 is provided between the normal temperature air drying mechanism 36 and the forming mechanism 33.

The production of a fiberboard using such an apparatus for producing a fiberboard is performed as follows. First, an impregnation step is performed by the impregnation mechanism 31 in the same manner as in FIG. Next, the long fiber mat 1 which has been subjected to the impregnation step is conveyed to the drying mechanism 32, where the long fiber mat 1 is conveyed by the conveying roller 35 and the room temperature air drying mechanism 36 applies the room temperature air from above to the long fiber mat 1. 3 is blown and supplied to remove the moisture 2a until the moisture content of the long fiber mat 1 becomes 100% or less, and then dried.
The room temperature air drying step is performed according to 6. At this time, the fiber can be dried until the water content becomes 100% or less by a method such as measuring a weight change of the long fiber mat 1 before and after the drying step. Can be manufactured. Next, the long fiber mat 1 is further dried by blowing air 4 of 40 ° C. or more from above onto the long fiber mat 1 by the hot air drying mechanism 37 while conveying the long fiber mat 1 by the transport roller 35 to supply the long fiber mat 1. The hot air drying mechanism 37 performs a hot air drying process. Here, unlike the batch-type heating and drying apparatus 30 as shown in FIG. 9, the long continuous fiber mat 1 can be dried while being conveyed by a conveyor such as a transport roller 35, so that continuous production can be easily performed. It is possible to respond. Next, a molding step is performed by the molding mechanism 33 in the same manner as in FIG. Thus, a fiberboard can be formed.

Since the room temperature air drying step by the room temperature drying mechanism 36 and the warm air drying step by the warm air drying mechanism 37 are used in the drying step, the adhesive component uniformly impregnated and adhered to the long fiber mat 1 by the impregnation step. After the long fiber mat 1 is dried in the room temperature air drying step without causing the movement of 2b, the long fiber mat 1 can be efficiently dried in the warm air drying step, and the molding time in the molding step can be efficiently reduced. This makes it possible to more easily produce a fiberboard having excellent adhesive performance.

FIG. 8 is a schematic view showing an example of another embodiment of the manufacturing apparatus of the present invention. This embodiment is a manufacturing apparatus for carrying out the embodiment shown in FIG. 4, and differs from the apparatus shown in FIG. The impregnation mechanism 31 shown in FIG. 8A and the forming mechanism 33 shown in FIG. 8D are the same as those in FIG.

The drying mechanism 32 includes a transport roller 35 for transporting the long fiber mat 1 obtained in the impregnation step,
As shown in FIG. 8B, a weak air drying mechanism 38 composed of a blower such as a fan 13 having a low air volume, and a strong air drying mechanism composed of a blower such as a blower 15 having a large air volume as shown in FIG. 39 are formed. That is, a weak air drying mechanism 3 having a weak air drying function for supplying the air 5 whose wind speed is controlled to 5 m / s or less to the long fiber mat 1 and drying it.
8 and a strong air drying mechanism 39 having a strong air drying function for supplying the air 6 whose wind speed is controlled to 10 m / s or more to the long fiber mat 1 and drying it.
Constitutes a drying mechanism 32. A plurality of transport rollers 35 are provided below the weak air drying mechanism 38 and the strong air drying mechanism 39, and are arranged in a direction parallel to the transport direction of the long fiber mat 1. The weak air drying mechanism 38 and the strong air drying mechanism 39 are disposed above the transport roller 35, and the weak air drying mechanism 38 and the strong air drying mechanism 39 are arranged in a direction parallel to the transport direction of the long fiber mat 1. ing.

The production of a fiberboard using such a fiberboard production apparatus is performed as follows. First, an impregnation step is performed by the impregnation mechanism 31 in the same manner as in FIG. Next, the long fiber mat 1 that has been subjected to the impregnation step is transported to the drying mechanism 32 (air drying mechanism 34). Is supplied from above by blowing air 5 having a wind speed of 5 m / s or less, and then blowing air 6 having a wind speed of 10 m / s or more by a strong wind drying mechanism 39 onto the long fiber mat 1 obtained in the weak wind drying process. Then, the water 2a is removed and dried until the water content of the long fiber mat 1 becomes 100% or less, and the air drying step is performed by the air drying mechanism 34. At this time, the moisture content was 100% by a method such as measuring the weight change of the long fiber mat 1 before and after the drying step.
Drying can be performed until the temperature becomes below, whereby a fiberboard having excellent adhesion performance can be easily manufactured. Next, a molding step is performed by the molding mechanism 33 in the same manner as in FIG. Thus, a fiberboard can be formed.

In the drying step, since the weak air drying step by the weak air drying mechanism 38 and the strong air drying step by the strong air drying mechanism 39 are used, the load on the long fiber mat 1 is reduced by using the weak air drying step. The long fiber mat 1 is dried without causing the movement of the adhesive component 2b uniformly adhered to the long fiber mat 1 by the impregnation process while suppressing as much as possible,
After the drying has progressed to some extent and the deformation of the long-fiber mat 1 does not occur, it can be further dried by using a strong wind drying step, and a fiber board having excellent adhesive performance can be more easily manufactured. At the same time
This makes it possible to effectively increase the drying efficiency.

[0071]

The present invention will be described below in detail with reference to examples.

(Example 1) Kenaf bast (width 1-2c)
m, a thickness of several mm, a length of about 2 to 4 m) is subjected to defibrating treatment, and the obtained kenaf long fiber mat 1 (fiber length of about 0.2 to 2 m, fiber diameter of about 50-600μ
m, the fiber was oriented in one direction), and a fiber board (kenaf long fiber board) was produced by the production apparatus shown in FIG. The long fiber mat 1 obtained at this time has a size of 300 × 900 m.
m, and the surface weight was 0.24 g / cm ² . As the adhesive 2, a urea-melamine adhesive was used. The operating condition is that the feed speed of the transport roller 11 is 0.5 m / sec.
c, the clearance of the transport roller 11 is 20 mm, the impregnation (immersion) time of the long fiber mat 1 is 10 seconds, and the squeeze roller 1 is
2, clearance 3 mm, air drying time 3 minutes, molding temperature 150 ° C., molding pressure 2.94 MPa (3
0 kgf / cm ² ) and a molding time of 5 minutes. Other conditions are described in Tables 1 and 2.

The size of the obtained board (fiberboard) was 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.80.

(Example 2) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The conditions were the same as in Example 1 except that the temperature of the hot air in the hot air drying mechanism 37 was set to 80 ° C., and the drying time of the hot air was set to 3 minutes.

The size of the obtained board (fiber board) is 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.79.

(Example 3) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The wind speed in the weak wind drying mechanism 38 is 4.5 m / sec, the air drying time is 4 minutes, and the wind speed in the strong wind drying mechanism 39 is 30 m / s.
ec, the same conditions as in Example 2 were used except that the air drying time was set to 1 minute.

The size of the obtained board (fiber board) is 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.78.

(Example 4) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The conditions were the same as in Example 3 except that the relative humidity of the air in the weak air drying mechanism 38 was set to 55%.

The size of the obtained board (fiberboard) was 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.81.

(Example 5) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The conditions were the same as in Example 3 except that the solid content ratio of the adhesive 2 was set to 45% and the relative humidity of air in the strong air drying mechanism 39 was set to 55%.

The size of the obtained board (fiber board) was 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.78.

(Example 6) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The same conditions as in Example 3 were used except that a water-soluble phenol adhesive was used as the adhesive 2, the solid content ratio was set to 30%, and the relative humidity of air in the strong air drying mechanism 39 was set to 60%. did.

The size of the obtained board (fiberboard) was 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.78.

(Example 7) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The conditions were the same as in Example 6, except that the solid content ratio of the adhesive 2 was changed to 20%.

The size of the obtained board (fiberboard) was 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.79.

(Example 8) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The conditions were the same as in Example 7, except that the clearance of the transport roller 11 immersed in the impregnation tank 7 was set to 5 mm.

The size of the obtained board (fiberboard) was 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.82.

(Example 9) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The conditions were the same as in Example 8, except that the thickness of the kenaf long fiber mat 1 was set to 10 mm, the porosity was set to 80%, and the clearance of the transport roller 11 immersed in the impregnation tank 7 was set to 1 mm.

The size of the obtained board (fiber board) is 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.77.

Example 10 Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The same conditions as in Example 9 were used, except that the adhesive 2 was impregnated using the kenaf long fiber mat 1 having a water content of 4.5%.

The size of the obtained board (fiber board) is 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.77.

Example 11 Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. The same conditions as in Example 9 were used, except that the adhesive 2 was impregnated with the kenaf long fiber mat 1 having a porosity of 90%.

The size of the obtained board (fiberboard) was 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.78.

(Comparative Example 1) Using the kenaf long fiber mat 1 obtained in the same manner as in Example 1, a fiber board (kenaf long fiber board) was produced by the manufacturing apparatus shown in FIG. A kenaf long fiber mat 1 having a porosity of 80% was used. Adhesive 2 having a solid content ratio of 30% was used. In the drying step, the heating and drying device 30 is used,
The drying temperature was set to 80 ° C. and the drying time was set to 25 minutes. Other conditions were the same as in Example 1.

The size of the obtained board (fiber board) was 3
The size was 00 × 900 mm, the thickness was 4 mm, and the specific gravity of the board was 0.83.

(Comparative Example 2) MDF used normally
(Medium density fiberboard) was used as a comparative example. The size of the MDF was 300 × 900 mm, the thickness was 4 mm, and the specific gravity was 0.83.

Tables 1 and 2 show the types and physical properties of the long fiber mat 1 and the adhesive 2 used in Examples 1 to 11 and Comparative Example 1 and the conditions in the impregnation step and the drying step.

The peel strength indicated in JIS A 5906 (medium density fiberboard) was tested as an index indicating the adhesive performance of the fiberboard, and the results are shown in Table 2.

[0099]

[Table 1]

[0100]

[Table 2]

As is evident from Table 2, it was confirmed that all of the examples of the present invention had high adhesive performance to Comparative Examples 1 and 2.

[0102]

As described above, according to the first aspect of the present invention, a water-soluble adhesive is impregnated in a long fiber mat composed of a large number of long fibers obtained from at least one of kenaf, oil palm and coconut palm. An impregnation step to be performed, a drying step of drying the long fiber mat obtained in the impregnation step, and a fiberboard manufacturing method comprising a molding step of forming the long fiber mat obtained in the drying step into a fiberboard by hot pressing, As the drying step, an air drying step of supplying air to the long fiber mat obtained in the impregnation step and drying until the water content becomes 100% or less is used, so that the inside of the long fiber mat is uniformly dried by the air drying step. It is possible to dry while applying a force in a direction opposite to a direction in which moisture and an adhesive component move to the surface of the long fiber mat during drying to the long fiber mat by supplying air. This makes it possible to uniformly dry the long fiber mat while suppressing the movement of the adhesive component uniformly adhered to the long fiber mat, thereby making it possible to easily produce a fiber board having excellent adhesion performance. .

[0103] The invention according to claim 2 of the present invention is characterized in that the drying step includes a normal temperature air drying step in which room temperature air is supplied to the long fiber mat obtained in the impregnation step to dry the long fiber mat until the water content becomes 100% or less. , 40 mm on the long fiber mat obtained in the room temperature air drying process.
It is composed of a hot air drying step of drying by supplying air at a temperature of at least ℃. Drying the long fiber mat while suppressing the movement of the adhesive component uniformly attached to the long fiber mat by the impregnation step in the normal temperature air drying step Easier to do,
This makes it possible to more easily produce a fiberboard having excellent adhesion performance, and to effectively increase the drying efficiency by a warm air drying step.

The invention according to claim 3 of the present invention is characterized in that the air-drying step comprises the steps of: supplying a continuous air having a velocity of 5 m / s or less to the long fiber mat obtained in the impregnation step; It is composed of a strong air drying step in which air with a wind speed of 10 m / s or more is supplied to the long fiber mat obtained in the step and drying is performed. Therefore, the impregnation step is performed while minimizing the load on the long fiber mat by the weak air drying step. The long fiber mat can be dried without causing the adhesive component uniformly attached to the long fiber mat to move, and the drying efficiency can be effectively increased by the strong air drying step.

According to the fourth aspect of the present invention, in the above-mentioned air drying step, dry air having a relative humidity of 60% or less is used, so that the drying efficiency can be more effectively increased in addition to the above-mentioned effects. It is.

According to the invention of claim 5 of the present invention, in the impregnation step, the solid content ratio of the adhesive is adjusted to 10 to 50%, so that the adhesive component can be effectively dispersed in the adhesive. This makes it possible to reduce the amount of the adhesive.

According to the sixth aspect of the present invention, since a water-soluble phenol adhesive is used as the adhesive, the adhesive component becomes very stable in the aqueous solution at the time of dilution.
The uniform adhesion of the adhesive component to the long fiber mat at the time of the impregnation step is further improved, and it is possible to easily produce a fiber board having more excellent adhesive performance.

According to the invention of claim 7 of the present invention, since the viscosity of the adhesive is adjusted to 10 to 300 mPa · s, the movement of the adhesive component during drying can be made more difficult to occur, and the long fiber mat can be formed by the impregnation step. The long fiber mat can be dried in a state in which the movement of the adhesive component uniformly adhered to the fiber is further suppressed, and a fiber board excellent in the adhesive performance can be manufactured more easily.

According to the invention of claim 8 of the present invention, in the impregnation step, the adhesive is impregnated in the long fiber mat whose thickness has been reduced by sandwiching it with a roller or the like, so that the air bubbles remaining between the long fibers are eliminated. Can effectively impregnate the inside of the long fiber mat with the adhesive, and can further improve the uniform adhesion of the adhesive component to the long fiber mat during the impregnation process, thereby further improving the bonding performance. Can be easily manufactured.

According to the ninth aspect of the present invention, the thickness is 3 to 2
Since the adhesive is impregnated into the long fiber mat adjusted to be 0 mm, the moving distance of the adhesive component in the thickness direction of the long fiber mat 1 can be reduced at the time of drying, and the uniform adhesion to the long fiber mat can be achieved by the impregnation process. The long fiber mat can be dried in a state in which the movement of the adhesive component is further suppressed, and a fiber board having excellent adhesive performance can be manufactured more easily.

According to the tenth aspect of the present invention, since an adhesive is impregnated in a long fiber mat adjusted so that the moisture content of the mat is 5% or less, a part of the adhesive component is partially impregnated on the surface of the long fiber during the impregnation step. The long fiber mat 1 can be dried in a state where it can be infiltrated into the vicinity and the movement of the adhesive component uniformly adhered to the long fiber mat by the impregnation process can be further suppressed. It is possible to manufacture it.

According to the eleventh aspect of the present invention, the porosity is 9%.
Since the adhesive is impregnated into the long fiber mat adjusted to be 0% or more, the moving path of the adhesive component in the thickness direction of the long fiber mat during drying can be reduced. The long fiber mat can be dried in a state in which the movement of the adhered adhesive component is further suppressed, and a fiber board having excellent adhesive performance can be more easily manufactured.

The twelfth aspect of the present invention is a drying apparatus having an impregnation mechanism for impregnating a long fiber mat with a water-soluble adhesive and an air drying function for supplying air to the long fiber mat for drying. Since it is equipped with a mechanism and a forming mechanism for forming into a fiberboard by hot pressing, it is possible to uniformly dry the long fiber mat while suppressing the movement of the adhesive component uniformly adhered to the long fiber mat by the impregnation process. Thus, it is possible to easily produce a fiber board having excellent adhesion performance, and it can be used as a production apparatus which can easily cope with continuous production.

[0114] The invention of claim 13 of the present invention provides a room temperature air drying function for supplying normal temperature air to the long fiber mat and drying, and a hot air drying function for supplying air of 40 ° C or more to the long fiber mat and drying. After drying the long-fiber mat without causing the movement of the adhesive component uniformly attached to the long-fiber mat 1 by the impregnation step, the long-fiber mat is further efficiently dried. Thus, the molding time during the molding step can be shortened, and a fiberboard having excellent adhesive performance can be more easily manufactured.

According to a fourteenth aspect of the present invention, there is provided a weak air drying function of supplying air having a wind speed of 5 m / s or less to the long fiber mat and drying the air, and supplying air having a wind speed of 10 m / s or more to the long fiber mat. It has an air drying mechanism with a strong air drying function that dries and dries, so that it is possible to dry the long fiber mat without causing the movement of the adhesive components uniformly attached to the long fiber mat by the impregnation process, and to improve the drying efficiency. Can be effectively increased.

[Brief description of the drawings]

1 shows an example of an embodiment of the present invention, in which (a) is a schematic diagram of an impregnation process, (b) is a schematic diagram of an air drying process, and (c) is a schematic diagram of a molding process.

FIGS. 2A to 2C are schematic diagrams illustrating a drying process of the present invention, and FIGS. 2D to 2F are schematic diagrams illustrating a conventional drying process.

FIG. 3 shows an example of another embodiment of the present invention, in which (a)
Is a schematic diagram of an impregnation process, (b) is a schematic diagram of a room temperature air drying process,
(C) is a schematic view of a hot air drying step, and (d) is a schematic view of a forming step.

FIG. 4 shows an example of another embodiment of the present invention, in which (a)
Is a schematic diagram of an impregnation process, (b) is a schematic diagram of a weak air drying process,
(C) is a schematic diagram of a strong air drying process, and (d) is a schematic diagram of a forming process.

5A and 5B show an example of the impregnation step of the above, wherein FIG. 5A is a schematic diagram and FIG. 5B is an enlarged schematic diagram.

FIG. 6 shows an example of another embodiment of the present invention, in which (a)
Is a schematic diagram of the impregnation mechanism, (b) is a schematic diagram of the drying mechanism,
(C) is a schematic diagram of a forming mechanism.

FIG. 7 shows an example of another embodiment of the present invention, in which (a)
Is a schematic diagram of the impregnation mechanism, (b) is a schematic diagram of the drying mechanism,
(C) is a schematic diagram of a forming mechanism.

FIG. 8 shows an example of another embodiment of the present invention, in which (a)
1 is a schematic view of an impregnation mechanism, (b) and (c) are schematic views of a drying mechanism (air drying mechanism), and (d) is a schematic view of a forming mechanism.

FIG. 9 shows a conventional example, in which (a) is a schematic diagram of an impregnation step,
(B) is a schematic diagram of a drying process, and (c) is a schematic diagram of a molding process.

FIG. 10 shows a conventional example, and (a) to (c) are schematic views of a drying step.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Long fiber mat 1 'Long fiber 2 Adhesive 2a Water 2b Adhesive component 3 Air 4 Air 5 Air 6 Air 8 Roller 31 Impregnation mechanism 32 Drying mechanism 33 Molding mechanism 34 Air drying mechanism

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Kenji Onishi 1048 Odakadoma, Kadoma City, Osaka Prefecture Matsushita Electric Works, Ltd. 72) Inventor Kazunori Umeoka 1048 Kazuma Kadoma, Kazuma, Osaka Prefecture F-term in Matsushita Electric Works Co., Ltd.

Claims (14)

[Claims] 1. An impregnating step of impregnating a water-soluble adhesive into a long fiber mat composed of a large number of long fibers obtained from at least one of kenaf, oil palm and coconut palm, and a long fiber mat obtained by the impregnation step In the method of manufacturing a fiberboard, comprising a drying step of drying and a forming step of forming the long fiber mat obtained in the drying step into a fiberboard by hot pressing, as a drying step, the long fiber mat obtained in the impregnation step is used. A method for producing a fiberboard, comprising using an air drying step of supplying air and drying until the water content becomes 100% or less. 2. The room temperature air drying step in which the room temperature air is supplied to the long fiber mat obtained in the impregnation step to supply the room temperature air to a moisture content of 100% or less, and the room temperature air drying step. The method for producing a fiberboard according to claim 1, characterized by comprising a hot-air drying step of supplying air of 40 ° C or more to the long fiber mat and drying. 3. The air-drying step includes a step of supplying air having an air velocity of 5 m / s or less to the long-fiber mat obtained in the impregnation step to dry the long-fiber mat, and a long-fiber mat obtained in the low-air air drying step. 3. The method for producing a fiberboard according to claim 1, comprising a strong air drying step of supplying air having a wind speed of 10 m / s or more to the air and drying the air. 4. The method of claim 1, wherein the relative humidity is 60% in the air drying step.
The method for producing a fiberboard according to any one of claims 1 to 3, wherein the following dry air is used. 5. The method for producing a fiberboard according to claim 1, wherein the solid content ratio of the adhesive is adjusted to 10 to 50% in the impregnation step. 6. The method according to claim 1, wherein a water-soluble phenol adhesive is used as the adhesive. 7. The adhesive has a viscosity of 10 to 300 mPa · s.
The method for producing a fiberboard according to any one of claims 1 to 6, characterized in that the adjustment is performed in the following manner. 8. The method for producing a fiberboard according to claim 1, wherein in the impregnation step, an adhesive is impregnated into a long fiber mat whose thickness has been reduced by being sandwiched between rollers or the like. . 9. The method for producing a fiberboard according to claim 1, wherein an adhesive is impregnated into a long fiber mat adjusted to have a thickness of 3 to 20 mm. 10. The method for producing a fiberboard according to claim 1, wherein an adhesive is impregnated in a long fiber mat adjusted so that the water content of the mat is 5% or less. 11. The method for producing a fiberboard according to claim 1, wherein an adhesive is impregnated in a long-fiber mat adjusted to have a porosity of 90% or more. 12. An impregnating mechanism for impregnating a long fiber mat with a water-soluble adhesive, a drying mechanism having an air drying function for supplying air to the long fiber mat for drying, and a fiberboard by hot pressure. An apparatus for manufacturing a fiberboard, comprising: a forming mechanism for forming a fiberboard. 13. A drying mechanism having a normal temperature air drying function of supplying room temperature air to the long fiber mat and drying, and a hot air drying function of supplying air of 40 ° C. or more to the long fiber mat and drying. The apparatus for producing a fiberboard according to claim 12, wherein the apparatus comprises: 14. A weak air drying function of supplying air having a wind speed of 5 m / s or less to the long fiber mat and drying, and a strong air drying function of supplying air having a wind speed of 10 m / s or more and drying the long fiber mat. The fiberboard manufacturing apparatus according to claim 12 or 13, further comprising an air drying mechanism provided.