JP5145280B2 - Method for producing functional fiber molded body - Google Patents

Description

  The present invention relates to a method for producing a functional fiber molded body containing vegetable fiber as a main material and containing functional powder particles.

A functional fiber molded body containing the above plant fiber as a main material and containing functional powder is used as an interior building material such as an inner wall material, a ceiling material, an underfloor material, or a heat insulating material of a building such as a residence. Or used as furniture materials for various furniture.
Such a functional fiber molded body is, for example, a granular (particulate) functionality having various functionalities such as a moisture absorbing / releasing material (humidity adjusting material), a deodorizing agent, an antibacterial agent, and the like. The powder is added to the vegetable fiber and molded.

For example, in the following Patent Document 1, a synthetic resin fiber material is contained as a binder in a granular humidity conditioning material having moisture absorption and desorption properties between the front and back layers in which a natural fiber material contains a synthetic resin fiber material as a binder. There has been proposed a humidity control board in which a laminated intermediate layer is formed by interposing and interposing and solidifying synthetic resin fiber materials of these layers by heat welding.
In Patent Document 1, as an example of a method for producing the humidity control board, natural fiber pieces and synthetic resin fiber pieces are deposited to form a lower mat body, and a humidity control material is sprayed from above the lower mat body, Furthermore, natural fiber pieces and synthetic resin fiber pieces are deposited thereon to form an upper mat body, and then, the laminated body is subjected to a needle punching process, whereby the fibers are entangled, An embodiment in which a board is manufactured by hot pressing is disclosed.

JP 2009-7741 A

However, as described above, a manufacturing process (manufacturing line) for manufacturing a functional fiber molded body in which a functional powder such as a humidity control material is added to a plant fiber to contain the functional powder. , Various processes are executed while being conveyed by a conveying means such as a belt conveyor. Alternatively, the intermediate molded product is manufactured by transferring between production lines where various processes are performed.
As described above, when transport or transfer is performed in a state where the functional powder is added to the vegetable fiber, the functional powder may fall out from between the plant fibers, There was a risk of scattering due to vibrations at the time. In particular, as described above, when the needle punching process is performed, there is a possibility that the above-described functional powder particles may fall off or be scattered.
Such a problem may be solved, for example, by adopting a so-called wet papermaking method in which fibers and particles are dispersed and mixed in fresh water. In this process, there is a problem that a long drying process is required.

  The present invention has been made in view of the above circumstances, and is a functional fiber molded body that can reduce the falling off and scattering of the functional powder and improve the yield of the functional powder while being a simple method. It aims at providing the manufacturing method of.

In order to achieve the above object, a method for producing a functional fiber molded body according to the present invention is a method for producing a functional fiber molded body containing vegetable fiber as a main material and containing functional powder. In addition, at least one of the plant fibers and the functional powder particles, in a state where the surface is sprayed to wet the surface, the functional powder particles are added to the plant fibers, After the functional powder is contained, the functional fiber molded body is produced by molding.
Here, the functional powder is a powder having various functions such as moisture absorption and deodorization, insect repellent, antibacterial, etc., and is granular, strip-like, particulate, fine particle Including powder and powder.

In the method for producing the functional fiber molded body according to the present invention, the functional powder is formed by depositing the plant fibers to form a mat-like lower layer portion and spraying the functional powder particles from above. After the addition of granules, the functional powder granules are dispersed, and then a vegetable fiber is further deposited thereon to form a mat-shaped intermediate molded body, and then the mat-shaped intermediate molded body, After performing the needle punching process and intertwining the plant fibers, they may be molded to produce a functional fiber molded body.
In the method for producing a functional fiber molded body including the step of performing the needle punching process, after forming the mat-like lower layer portion, before spraying the functional powder particles, the mat-like lower layer portion Then, the liquid is sprayed from above, and after the functional powder is sprayed, the liquid is sprayed from above before forming the mat-shaped intermediate molded body. Good.

In the method for producing any one of the functional fiber molded bodies according to the present invention, a particle diameter of the functional powder to be added may be less than 100 μm.
In the method for producing any one of the functional fiber molded bodies according to the present invention, the liquid may contain an adhesive.
In the method for producing any one of the functional fiber molded bodies according to the present invention, before the molding, a synthetic resin binder is further added, and heated and pressed to be cured into a board shape and molded. Also good.

According to the method for producing a functional fiber molded body according to the present invention, at least one of the plant fiber and the functional powder body is sprayed with a liquid and the surface is wetted, Since the functional powder is added to the vegetable fiber, the functional powder is easily attached to the vegetable fiber. Therefore, it is possible to reduce that the functional powder particles fall out between the plant fibers or scatter due to vibration or the like during transportation or the like in the manufacturing process, and by a simple method. The yield of functional powder can be improved. Thereby, the functional fiber molded object which can fully exhibit the functionality which a functional granular material has can be manufactured.
Moreover, since the spraying of the liquid may be a spraying amount so as to wet at least one of the surface of the plant fiber and the functional powder, it is necessary in the wet papermaking method as described above. The long drying process etc. which become are unnecessary, and a functional fiber molded object can be manufactured with a dry-type manufacturing method.

In the method for producing a functional fiber molded body according to the present invention, the functional fiber granules are formed by depositing the plant fibers to form a mat-like lower layer portion and spraying the functional powder granules from above. After adding the body and spraying the functional powder particles, vegetable fibers are further deposited thereon to form a mat-shaped intermediate molded body, and then a needle is applied to the mat-shaped intermediate molded body. If the plant fiber is entangled by performing a punching process and then molded to produce a functional fiber molded body, the following effects are obtained.
That is, since at least one of the plant fiber and the functional powder is in a state where the liquid is sprayed and the surface is wet, the function due to the vibration is also performed when the needle punching process is performed. The falling off and scattering of the powdery granular material can be reduced. Moreover, since vegetable fiber is intertwined by needle punching process, the intensity | strength of a functional fiber molded object can be raised.

In the method of manufacturing a functional fiber molded body including the step of performing the needle punching process, after forming the mat-like lower layer portion, before spraying the functional powder particles, the mat-like lower layer portion In addition, after spraying the liquid from above, and after spraying the functional powder, before forming the mat-shaped intermediate molded body, spraying the liquid from above, It is possible to more effectively reduce the falling off and scattering of the functional powder.
That is, since the liquid is sprayed on the surface of the mat-like lower layer before the functional powder is sprayed, the functional powder sprayed on the upper surface is efficiently attached. be able to. Further, since the liquid is further sprayed after the functional powder particles are sprayed, the functional powder particles can be densely packed in a pseudo-aggregated state and deposited in the subsequent steps. Adhesion with vegetable fibers can be improved. Thereby, dropping-off, scattering, etc. of a functional granular material can be reduced more efficiently.

In the method for producing any one of the functional fiber molded bodies according to the present invention, if the particle diameter of the functional powder to be added is less than 100 μm, such fine particle functional powder Since there is a tendency to agglomerate to some extent, when the vibration during conveyance or the like is relatively small, the dropout between the plant fibers tends to be relatively small. On the other hand, since it is in the form of fine particles, it tends to scatter due to the influence of vibration or the like during transportation or when various processes are performed. Even when the particles are employed, the functional powder particles can be effectively eliminated from falling off and scattered.
In addition, by adopting such fine particle functional powder, for example, even when the functional fiber molded body is formed in a thin board shape, in the thickness and in the surface area direction, It is possible to reduce the occurrence of density difference, thickness difference, etc., and to manufacture a homogeneous board efficiently. Thereby, the smoothness of the surface of the board can also be improved.

  In the method for producing any one of the functional fiber molded bodies according to the present invention, when the liquid contains an adhesive, the functional powder is more effectively added to the vegetable fiber. It becomes easy to adhere and the above-mentioned functional granular material can be more effectively reduced from falling off and scattering.

In the method for producing any one of the functional fiber molded bodies according to the present invention, if the synthetic resin binder is further added prior to the molding, the resin is heated and pressed to be cured into a board shape and molded. As described above, it is possible to produce a board that can sufficiently improve the yield of the functional powder particles and sufficiently exhibit the functionality of the functional powder particles.
In particular, when the board is relatively thin, it is possible to add a functional powder having a relatively small particle diameter to reduce local density difference or thickness difference to the board. It is preferable from the viewpoint of not generating it. In the case of adding such a functional particle having a small particle size, it tends to scatter due to vibration or the like particularly during conveyance or when various processes are performed. As described above, this can be prevented. Therefore, functional particles having a relatively small particle size can be efficiently added, and the yield of the functional particles can be improved by a simple method. In addition, if functional powders with such a small particle size are added to plant fibers to form a thin board, local density differences and thickness differences are unlikely to occur, and the surfaces are compared. Can be smooth and smooth, and a homogeneous board can be formed.

It is a conceptual explanatory drawing for demonstrating a part of one Embodiment of the manufacturing method of the functional fiber molded object which concerns on this invention. It is a conceptual explanatory view for explaining a part of the manufacturing method. It is a conceptual explanatory view for explaining a part of the manufacturing method. It is a table | surface which shows an example of the Example of a functional fiber molded object manufactured using the manufacturing method, a comparative example, and a reference example with the result of an evaluation test.

Embodiments of the present invention will be described below with reference to the drawings.
FIGS. 1-3 is a conceptual explanatory drawing for demonstrating an example of the manufacturing method of the functional fiber molded object which concerns on this embodiment. FIG. 4 is a table showing an example, a comparative example, and a reference example of the functional fiber molded body manufactured by using the manufacturing method, together with the result of the evaluation test.

The functional fiber molded body manufactured by the method for manufacturing a functional fiber molded body according to the present embodiment is a functional fiber board 19 formed in a board shape (flat plate shape) as shown in FIG. .
As shown in FIG. 1, the functional fiber board 19 has vegetable fiber 11 as a main material, and, as will be described later, synthetic resin fiber 12 as a binder is added to and mixed with the vegetable fiber 11, and further, After the liquid 14 is sprayed on the surfaces of the fibers 11 and 12, the functional powder 13 is added, and after various steps as described later, it is heated and pressed to be formed into a board shape.

The functional fiber board 19 can be used as interior building materials (surface building materials) such as sliding doors, folding doors, hinged doors (door panels), inner walls, partitions, shelves, kitchen panels, ceilings, etc. It can be used as a heat insulating material such as a wall insulation material or a front plate (door) of a storage furniture such as a cabinet, a top plate, a shelf plate, a side plate, a bottom plate, a back plate, or the like.
Moreover, you may make it adhere | attach further the decorative sheet, wallpaper, etc. which have air permeability for surface finishing suitably on the surface of this functional fiber board 19 according to a use aspect.
Further, a plaster board, a wooden board, a resin board, or the like may be further adhered to the back surface of the functional fiber board 19 depending on the usage mode.

Examples of the plant fibers 11 employed in the functional fiber board 19 include bast fibers collected from plant basts (for example, the toughness of hemp plants such as kenaf, flax, ramie, cannabis and jute). Fibers collected from the skin), fibers collected from the stems or edges of hemp plants such as Manila hemp and sisal hemp, fibers collected from palm plants such as oil palm and coconut palm, and wood fibers such as pulp Is mentioned.
In particular, if a hemp plant fiber or coconut plant fiber obtained from a hemp plant or coconut plant that is a non-timber resource is used as the plant fiber 11 instead of a wood resource that has recently been depleted, The functional fiber board 19 in consideration of environmental resources can be manufactured. Moreover, the fiber extract | collected from such a hemp plant and palmaceous plant has a tensile strength about 2 to 14 times larger than the fiber extract | collected from the conifer and the hardwood used for the conventional fiber board. Therefore, by adopting fibers collected from these hemp plants and palm plants in the functional fiber board 19, the strength of the functional fiber board 19 itself can be increased more effectively, and interior building materials and furniture materials can be obtained. And so on.

In addition, you may employ | adopt the said various fibers in combination of 1 type, or 2 or more types.
Moreover, what is necessary is just to adjust a compounding ratio so that the said vegetable fiber 11 may become a main material, and it is also possible to mix and mix artificial mineral fibers such as rock wool, slag wool, mineral wool, and glass wool. Good.

The vegetable fiber 11 may be a long fiber. For example, the fiber length may be about 6 mm to 2000 mm, preferably about 10 mm to 200 mm, and more preferably about 20 mm to 100 mm.
When the fiber length of the vegetable fiber 11 is shorter than the above range, the fibers are not easily entangled, and the strength and air permeability of the board itself tend to be reduced, and the fiber length is longer than the above range. And, as will be described later, when the mat-like intermediate molded body 17 is formed by the vegetable fiber 11, there is a tendency that it is difficult to obtain a predetermined shape.
The average fiber diameter of the vegetable fiber 11 may be 20 μm to 500 μm, preferably defibrated so as to be about 50 μm to 200 μm.
If the average fiber diameter of the plant fiber 11 is smaller than the above range, the bonding area between the fibers increases, so that the strength of the board itself is increased, but the gap between the fibers is reduced, and air permeability is inhibited. Tend to. Moreover, when the average fiber diameter is larger than the above range, the gap between the fibers becomes large and the air permeability becomes high, but the adhesion area between the fibers decreases and the strength of the board itself tends to decrease.

The synthetic resin fiber 12 as the synthetic resin binder (adhesive component) employed in the functional fiber board 19 includes fibers made of a thermoplastic resin such as polyester, polypropylene, polyethylene, polyethylene terephthalate, nylon, and polylactic acid resin. The fiber etc. which consist of are mentioned. In addition, the fiber length and fiber diameter of the synthetic resin fiber 12 may be the same as those of the vegetable fiber 11. The various synthetic resin fibers 12 may be used alone or in combination of two or more. For example, a polyester resin is used as a core (core component), and nylon, polyethylene, ethylene-vinyl alcohol resin, or the like is used as a sheath. It is good also as the synthetic resin fiber 12 of the core-sheath structure used as the part (sheath component).
When such a synthetic resin fiber 12 is used as a binder, the vegetable fiber 11 is appropriately entangled with each other, and the synthetic resin fiber 12 is melted by hot pressing and then cured, so that the vegetable fiber It functions as a binder for connecting and solidifying 11 together. Thus, an appropriate space | gap can be maintained by using the synthetic resin fiber 12 as a binder.

In addition, in order to make the synthetic resin fiber 12 and the vegetable fiber 11 easy to entangle with each other or to improve the entanglement (capturing property) of the functional granular material 13, as a pretreatment, a vegetable fiber bundle is used. And the synthetic resin fiber bundle may be defibrated simultaneously. By passing through such a defibrating process in several stages, the plant fibers and the synthetic resin fibers are appropriately mixed while being defibrated to form a cotton-like defibrated mixture (defibrated mixed cotton). The The defibrated mixed cotton may be dispersed from the defibrated mixed cotton into the vegetable fiber (piece) 11 and the synthetic resin fiber (piece) 12 by a fiber disperser 21, as will be described later.
Further, the synthetic resin binder (adhesive component) is not limited to a fibrous one as described above, and a powdery thermoplastic resin binder is employed instead of or in addition to the synthetic resin fiber 12. It may be.
Furthermore, it is not limited to those composed of the above-mentioned thermoplastic resin, but as a powdery binder containing a thermosetting resin such as urea resin, melamine resin, urea-melamine cocondensation resin, phenol resin, epoxy resin, urethane resin Also good.

The blending ratio of the synthetic resin binder (synthetic resin fiber 12 in this embodiment) to the vegetable fiber 11 (ratio of the synthetic resin binder in the total weight in the state where the vegetable fiber 11 and the synthetic resin binder are mixed) is The solid content may be about 10% to 60% by weight, preferably about 20% to 50% by weight. This makes it possible to manufacture a functional fiber board 19 that can sufficiently exhibit the functionality of the functional powder 13 described later without impairing air permeability (moisture permeability), and adhesion between the plant fibers 11. Can increase the sex.
If the ratio of the synthetic resin binder is smaller than the above, the vegetable fiber 11 tends not to be sufficiently solidified by melting and curing the synthetic resin fiber 12 as will be described later. Tend to disperse, the surface hardness decreases, and peeling occurs. Moreover, if the ratio of the synthetic resin binder is larger than the above, the adhesiveness between the plant fibers 11 is enhanced, but the air permeability (moisture permeability) of the board itself tends to be inhibited, and the functions described later. There is a tendency that a gap for capturing the powder 13 between the fibers is not sufficiently secured.

The functional powder body 13 employed in the functional fiber board 19 includes a moisture conditioning material having moisture absorption / release properties, a deodorant having a deodorizing property, an insect repellent having an insecticidal property, and an antibacterial agent. The antibacterial agent or catalyst which has the property, a natural material, etc. are mentioned, Any things, such as a granular form, a fine piece form, a particulate form, fine particle form, and a powder form, may be sufficient.
Examples of the humidity control material include charcoal such as charcoal and bamboo charcoal, talc, zeolite, diatomaceous earth, silica gel (preferably B-type silica gel), clay minerals such as montmorillonite and sepiolite, and inorganic materials such as alumina and silica. . Alternatively, the humidity control material may be a particulate polymer moisture absorbing / releasing material (organic polymer moisture absorbing / releasing material). This polymer moisture-absorbing / releasing material has a reversible moisture-absorbing function and moisture-releasing function. For example, a polymer obtained by polymerizing acrylic acid, methacrylic acid or the like as a main component, or a polymer nitrile containing acrylonitrile as a main component. Examples thereof include acrylic resins having a crosslinked structure such as those obtained by hydrolyzing a group.

The particle diameter of the functional powder 13 is 2.0 mm or less, preferably 300 μm or less, and more preferably less than 100 μm.
In the case of producing a board-shaped functional fiber molded body as in the present embodiment, the thickness of the functional powder 13 is generally about 2.0 mm to 12 mm. Increasing the diameter tends to cause local density differences, thickness differences, etc., and the strength of the board may be reduced.
In particular, if the particle size of the functional powder 13 is 300 μm or less, for example, when a relatively thin board having a thickness of about 2.0 mm to 5.0 mm is manufactured, it is locally Therefore, a relatively uniform board can be manufactured. On the other hand, if the thickness is 300 μm or less as described above, it is dropped or scattered from the gap between the fibers 11 and 12 due to the influence of vibration or the like when conveyed in the manufacturing process described later or when each process is performed. However, as will be described later, in the present embodiment, this can be reduced.

Moreover, if the particle size of the functional powder 13 is less than 100 μm, it is possible to more effectively reduce the occurrence of the above-mentioned local density difference, thickness difference, etc. A homogeneous board can be manufactured even when the above is manufactured. In addition, such a fine particle-like functional powder 13 tends to have a small bulk density and moderately tend to aggregate the particles. Therefore, when vibration during transportation is relatively small, The omission from between the plant fibers 11 tends to be relatively small. On the other hand, since it is in the form of fine particles, it tends to be affected by vibrations and the like during conveyance in the manufacturing process described later and when various processes are performed, and tends to scatter. As such, this can be reduced.
The particle size of the functional powder 13 is not particularly limited, but may be 10 μm or more from the viewpoint of handling and cost. Moreover, you may employ | adopt the said various functional granular material 13 combining 1 type, or 2 or more types.
Moreover, it is good also as an aspect which mixes and employ | adopts the functional granular material 13 from which average particle diameter differs, for example, silica gel with a comparatively large particle diameter, a fine powder deodorant, an antibacterial agent, etc.

In the manufacturing process described later, the liquid 14 to be sprayed may be any liquid as long as it is liquid such as water. Alternatively, an adhesive-containing solution 14 in which an adhesive is dissolved or dispersed in water or another solvent may be used. As such an adhesive-containing solution, an acrylic emulsion or the like that has adhesiveness before heating and is dried and cured by heating as described later is preferable. In addition, the pressure-sensitive adhesive-containing solution may be an aqueous emulsion, a starch solution in which processed starch or the like is dissolved, a diluted aqueous paste, or the like.
Alternatively, instead of or in addition to the pressure-sensitive adhesive-containing solution 14 as described above, a silica sol solution may be sprayed in order to improve (or impart) humidity control properties.

Next, an example of a method for producing a functional fiber molded body according to the present embodiment will be described with reference to FIGS.
<Matte lower layer forming step 1>
In this mat-like lower layer forming step 1, as shown in FIG. 1, a defibrated mixed cotton comprising the vegetable fiber 11 and the synthetic resin fiber 12 mixed as described above and made cotton-like is supplied. The defibrated mixed cotton from the feeder 20 is supplied to the fiber disperser 21 via the belt conveyor 20a.
In this fiber disperser 21, the above-described cotton-like defibrated mixed cotton is dispersed and deposited on the main conveyor 24 below by rotating a roller body provided with a large number of scraping blades on its peripheral surface. . That is, the mat-like lower layer portion 15 is formed by depositing and laminating the vegetable fiber 11 and the synthetic resin fiber 12 while being dispersed on the main conveyor 24.
In this state, the vegetable fiber 11 and the synthetic resin fiber 12 are laminated in a state of being appropriately mixed at the above-described predetermined blending ratio.

In addition, after depositing as described above, each of the fibers (vegetable fiber 11 and synthetic resin fiber 12) is subjected to combing treatment so as to be oriented in approximately one direction, or in approximately two orthogonal directions. Combing treatment may be performed so as to be oriented.
Further, the basis weight of the fibers 11, 12 of the mat-like lower layer portion 15 formed in the mat-like lower layer portion forming step 1 and the mat-like upper layer portion 16 formed in the mat-like intermediate molded body forming step 5 described later is the present production. It can be set as appropriate according to the density and thickness of the functional fiber board 19 (see FIG. 3) manufactured in the process.

<First liquid spraying step 2>
Next, the liquid 14 is uniformly applied over the entire upper surface of the mat-like lower layer 15 by the liquid spreader 22 from above the mat-like lower layer 15 deposited and formed in a mat shape as described above. Scatter. The liquid spreader 22 may be a spray type sprayer that sprays the liquid 14 in the form of a mist.
The dispersion amount of the liquid 14 can be set as appropriate according to the basis weight of the fibers 11 and 12 constituting the mat-like lower layer portion 15, but at least each fiber exposed on the upper surface of the mat-like lower layer portion 15. The amount of the surface may be sufficiently wetted, or the amount may be dried and cured in the heating and pressing step 7 described later. For example, it may be about 5 g / scale angle (45 g / m ² ) to about 20 g / scale angle (180 g / m ² ).

<Functional granular material application process 3>
As described above, with respect to the mat-like lower layer portion 15 in which the liquid 14 is dispersed on the upper surface, the functional powder 13 is applied from above to the upper surface of the mat-like lower layer portion 15 by the powder-dispersing machine 23. Spread evenly over the entire area.
As described above, since the liquid 14 is sprayed on the upper surface of the mat-like lower layer portion 15 and the surfaces of the fibers 11 and 12 are wet, the mat-like shape conveyed on the main conveyor 24 in this way. Even when the functional granular material 13 is sprayed on the lower layer portion 15, the functional granular material 13 easily adheres to the fibers 11 and 12, and is captured in the gaps between these fibers 11 and 12. It becomes a state or a state where it is deposited on the upper surface, and can be prevented from falling off or scattering.

It is preferable that the powder and powder spreader 23 can spread a substantially fixed amount of the functional powder 13 over the entire upper surface of the mat-like lower layer 15.
As such a granular material spreader 23, you may make it apply well-known quantitative supply apparatuses of a granular material, such as a vibration feeder and a screw feeder, for example.
The amount of the functional powder particles 13 to be applied is appropriately set according to the usage mode of the functional fiber molded body, the basis weight of the mat-shaped intermediate molded body 17 including the mat-shaped lower layer portion 15 described later, and the like. Although it is possible, when it is set as the functional fiber board 19 shape | molded by heating and pressurizing and making it board-shaped like the postscript, it inhibits the connection solidification of the vegetable fiber 11 by the said synthetic resin fiber 12. It is preferable that the amount of application is such that there is not. For ^example, it may be about ^{50g / m 2 ~1000g / m 2} .

<Second liquid spraying step 4>
As described above, from the upper part of the mat-like lower layer portion 15 on which the functional powder particles 13 are dispersed on the upper surface, the liquid 14 is further dispersed by the liquid spreader 22 in the same manner as in the first liquid spraying step 2. It sprays so that it may become uniform over the whole upper surface of the mat-like lower layer part 15. FIG.
Thus, by spraying the liquid 14 to the mat-like lower layer portion 15 on which the functional powder particles 13 are sprayed on the upper surface, the functional powder particles 13 can be densely packed in a pseudo-aggregated state. At the same time, adhesion to the fibers 11 and 12 can be enhanced. Thereby, like the above, it is possible to more efficiently reduce the falling off, scattering, and the like of the functional granular material 13 during conveyance up to the subsequent process and when the subsequent process is performed.

Note that the liquid 14 sprayed in the second liquid spraying step 4 and the first liquid spraying step 2 may be the adhesive-containing solution 14 as described above. According to this, the adhesiveness with respect to each fiber 11 and 12 of the said functional granular material 13 can be improved more effectively, and omission, scattering, etc. can be prevented more effectively.
Further, the spray amount of the liquid 14 in the second liquid spraying step 4 may be the same spray amount as the first liquid spraying step 2 or a smaller spray amount than the first liquid spraying step 2.

<Matte intermediate molded body forming step 5>
Next, as shown in FIG. 2, the mat-like lower layer portion 15 on which the functional powder particles 13 are captured or deposited as described above is conveyed by the main conveyor 24 to form the mat-like upper layer portion 16. The intermediate intermediate product 17 is formed.
That is, as in the mat-like lower layer forming step 1, the defibrated mixed cotton from the feeder 20 is supplied to the fiber disperser 21 via the belt conveyor 20a, and the plant dispersal fiber 21 is used by the fiber disperser 21. The synthetic resin fibers 12 are deposited and laminated while being dispersed on the upper surface of the mat-like lower layer portion 15 on which the functional powder 13 is captured or deposited, thereby forming the mat-like upper layer portion 16. As a result, a mat-like intermediate molded body 17 is formed in which the mat-like lower layer portion 15, the functional granular material 13 layer serving as the intermediate layer, and the mat-like upper layer portion 16 are generally laminated in order from the bottom.
Since the liquid 14 is dispersed on the upper surface of the mat-like lower layer portion 15 on which the functional powder 13 is captured or deposited as described above, the fibers 11 and 12 dispersed and deposited on the upper surface and the function As described above, the functional powder 13 is more easily attached, and the functional powder 13 is more efficiently reduced from being dropped or scattered during transport to the subsequent process and when the subsequent process is performed. be able to.

<Needle punching process 6>
The mat-like intermediate molded body 17 formed as described above is introduced into the needle punch machine 26 while adjusting the thickness via the thickness adjusting roller 25. In this needle punching machine 26, a large number of needles (needle) having barbs (protrusions) are reciprocated up and down at a high speed, whereby the mat-like lower layer portion 15 and the mat-like upper layer portion 16 stacked as described above are used. The fibers 11 and 12 are entangled (entangled). By performing the needle punching process in this way, the fibers 11 and 12 are more entangled with each other, and the mat-like lower layer portion 15 and the mat-like upper layer portion 16 are connected so as to be sewn together. Further, the functional powder particles 13 deposited between the mat-like lower layer portion 15 and the mat-like upper layer portion 16 as described above are appropriately dispersed in the thickness direction.

  Even when the needle punching process is performed, as described above, the functional powder particles 13 included in the mat-shaped intermediate molded body 17 are adhered to the fibers 11 and 12 by the dispersion of the liquid 14. Since it is raised, it is possible to prevent omission and scattering. In particular, when the above-described fine functional particles 13 having a particle size of less than 100 μm are employed, as described above, there is a tendency that falling off with a small vibration tends to decrease due to moderate aggregation. When large vibrations such as processing occur, there is a tendency for dropout and scattering to increase. According to the present embodiment, even when such a large vibration occurs, the adhesion to the functional powder particles 13 and the fibers 11 and 12 is enhanced. 13 can be prevented from falling off and scattered.

<Heating and pressing step 7>
Next, the mat-like intermediate molded body 17 that has been subjected to the needle punching process is introduced into a heating and pressing machine 27 as shown in FIG. In the heating and pressing machine 27, the synthetic resin fibers 12 are melted and the plant fibers 11 are connected and solidified. The heating and pressing machine 27 can preliminarily press the mat-like intermediate molded body 17 at a relatively low pressure and heat the synthetic resin 17 so as to have a certain degree of shape retention. Any material can be used as long as it can melt the fiber 12.
<Ventilation cooling process 8>
A suction unit (not shown) such as a blower from below while the mat-like intermediate molded body 17 that has been heated and pressed by the heating and pressing machine 27 and led out from the heating and pressing machine 27 is being transported by the mesh conveyor 28a. Is sucked by the suction means 28 provided with the air to cool the mat-like intermediate molded body 17 by passing air at normal temperature. Thereby, the synthetic resin fiber 12 melted as described above is cured, and the functional fiber mat 18 is formed. In this state, it will be in the state which hardened to such an extent that it could carry.
<Preliminary cutting step 9>
The functional fiber mat 18 that has been cured to some extent as described above is cut into a predetermined size by a cutting machine 29 so that the functional fiber mat 18 can be introduced into the hot press machine 30 in the hot press step 10 described later. To do.

<Hot press (heat pressurization) process 10>
Next, the functional fiber mat 18 is introduced into a hot press machine (hot press machine) 30 provided with a pair of press plates, and hot press (heat press) is performed. The conditions during the hot pressing, that is, the pressing pressure, the pressing time, and the press die surface temperature are determined by the weight of each of the fibers 11 and 12 included in the functional fiber mat 18 and the density of the functional fiber board 19 after molding. It can be appropriately set according to the thickness of the plate, the type of the synthetic resin binder (melting temperature, curing temperature, etc.) and the content.
Moreover, you may make it heat-press so that the density of the functional fiber board 19 after shaping | molding may be 500 kg / m < ³ > or more and 1200 kg / m < ³ > or less at the time of the said heat press. As a result, the strength of the functional fiber board 19 after molding can be increased and the air permeability thereof is not hindered, so that the functionality of the functional powder body 13 contained therein can be sufficiently exhibited. The fiber board 19 can be manufactured.

When the density of the functional fiber board 19 is less than 500 kg / m ³ , the surface hardness and strength of the functional fiber board 19 tend to decrease, and the holding power of nails, wood screws, and the like tends to decrease. is there. Moreover, when the density of the functional fiber board 19 is more than 1200 kg / m ³ , the air permeability of the functional fiber board 19 tends to be low.
After performing the hot press as described above, the mold is removed, and appropriately cut into a predetermined size to produce the functional fiber board 19. The functional fiber board 19 formed in this way becomes a breathable porous (matrix) state due to the entanglement of the vegetable fiber 11 connected and solidified by the synthetic resin fiber 12 as described above, and the entanglement is achieved. As described above, the functional powder board 13 is appropriately dispersed between the plant fibers 11 and is captured and contained.

As described above, according to the method for producing a functional fiber molded body according to the present embodiment, the functional powder particles 13 are easily attached to the fibers 11 and 12 by the dispersion of the liquid 14. In each step, it is possible to reduce falling off or scattering between the fibers 11 and 12, and to improve the yield of the functional granular material 13 by a simple method. Thereby, the functional fiber board 19 which can fully exhibit the functionality which the functional granular material 13 has can be manufactured.
In addition, since the functional powder particles 13 can be prevented from falling off or scattering in this way, for example, the functional powder particles 13 having a relatively small particle diameter of 300 μm or less, more preferably less than 100 μm are employed. Can do. Thereby, for example, when manufacturing a functional fiber board 19 having a relatively thin plate thickness of about 2.0 mm to 5.0 mm, local density differences and thickness differences are less likely to occur. A homogeneous functional fiber board 19 can be produced. Thereby, the smoothness of the surface of the functional fiber board 19 can also be improved.

In addition, in each said process, although the aspect which processes and shape | molds an intermediate molded product continuously, conveying by each conveyor and each apparatus, such as the main conveyor 24, is illustrated, for example, each intermediate | middle made into the stationary state It is good also as an aspect which moves each apparatus with respect to a molded article and performs each process. In this case, it may be sequentially conveyed or transferred by a conveyor or other transfer means for the next step.
Further, in the mat-like lower layer portion forming step 1 and the mat-like intermediate molded body forming step 5, the defibrated mixed cotton obtained by mixing the synthetic resin fibers 12 with the vegetable fibers 11 is dispersed and deposited to form the mat-like lower layer portion 15 and the mat. Instead of or in addition to the aspect of forming the upper layer portion 16, the powdery binder described above may be added to and mixed with the vegetable fiber 11.
Or it is good also as an aspect which manufactures the functional fiber board 19 by a normal temperature press, for example, without including the above synthetic resin binders.

Furthermore, instead of the above-described embodiment in which the defibrated mixed cotton is dispersed and deposited to form the mat-like lower layer portion 15 and the mat-like upper layer portion 16, for example, it is formed in a mat shape to the extent that it can be carried. The mat body may be laminated with the functional powder particles 13 interposed therebetween to form the mat-shaped intermediate molded body 17.
Alternatively, instead of an embodiment in which the defibrated mixed cotton is dispersed and deposited as described above to form the mat-like lower layer portion 15 and the mat-like upper layer portion 16, the vegetable fiber 11 is dispersed and deposited alone, and then The synthetic resin fiber 12 is dispersed and deposited alone to form a mat-like lower layer portion, and the synthetic resin fiber 12 is dispersed and deposited alone, and then the plant fiber 11 is dispersed and deposited alone. It is good also as an aspect which makes it make it form a mat-like upper layer part. Even in this case, the fibers 11 and 12 can be appropriately entangled with each other by performing the needle punching process.

Furthermore, in this embodiment, the aspect which performs a needle punching process with respect to the mat-like intermediate molded body 17 formed by laminating | stacking the mat-like lower layer part 15, the functional granular material 13, and the mat-like upper layer part 16 is carried out. Although illustrated, it is good also as an aspect which performs each process after the said heating press-fit process 7 without performing the said needle punching process process 6 with respect to the said mat-shaped intermediate molded object 17. FIG.
Or it replaces with the aspect which laminates | stacks the mat-like lower layer part 15, the functional granular material 13, and the mat-like upper layer part 16 as mentioned above, for example, among the said defibrated mixed cotton and the said functional granular material 13 After spraying the liquid 14 with at least one of the liquid sprayers 22, the functional powder 13 is sprayed on the plant fibers 11 and the synthetic resin fibers 12 dispersed as described above. The mat-shaped intermediate molded body 17 may be formed by depositing these. In such an aspect, for example, the fibers 11 and 12 and the functional granular material 13 are mixed by generating an air current by at least one of a blower and a blower such as a blower and a fan. It is good also as an aspect which deposits and forms the said mat-shaped intermediate molded object 17. FIG.

In the present embodiment, the spraying of the liquid 14 is exemplified in the first liquid spraying process 2 and the second liquid spraying process 4, but only one of them may be performed. Good.
Furthermore, for example, it is set as the aspect which sprinkles the liquid 14 with respect to the defibrated mixed cotton of the state before forming the mat-like lower layer part 15, or the functional powder particle which is sprayed and supplied from the said powder body spraying machine 23 For example, the liquid 14 may be sprayed on the body 13.
Furthermore, in the present embodiment, after the functional fiber mat 18 is formed as described above, an example in which the functional fiber mat 18 is formed into a board shape by heating and pressing is illustrated. However, the present invention is not limited to this, and a non-board-shaped molded body having irregularities and curved surfaces may be manufactured.
Further, for example, the mat-shaped molded product having a relatively low density, that is, the functional fiber mat 18 may be grasped as the functional fiber molded product without heating and pressing.

  Furthermore, in this embodiment, the functional fiber mat 18 that has undergone the heating and pressing step 7 and the ventilation cooling step 8 is cut in the preliminary cutting step 9, introduced into the hot press machine 30, and illustrated as an example of heating and pressing. However, without passing through the heating and pressing step 7, the air cooling step 8 and the preliminary cutting step 9, for example, the mat-like intermediate molded body 17 is introduced into the heating and pressing roller, It is good also as an aspect which performs a heating-pressing process continuously.

Next, an example of a functional fiber molded body manufactured using the method for manufacturing a functional fiber molded body according to the present embodiment, a comparative example, and a reference example are shown in FIG. This will be explained based on.
In each example shown in FIG. 4, jute is adopted as the vegetable fiber 11, and polyester fiber having a core-sheath structure in which the sheath portion has a melting temperature of 110 ° C. is adopted as the synthetic resin fiber 12. Using the above-mentioned defibrated mixed cotton blended with 50% by weight of each of these, the mat-like lower layer portion forming step 1 and the mat-like intermediate so that the total weight of these fibers 11 and 12 is about 1500 g / m ^2. The molded object formation process 5 was performed.
In each example shown in FIG. 4, the functional powder 13 employs B-type silica gel as a humidity control material, and the above-mentioned functional powder is applied so that the amount of the silica gel sprayed is about 200 g / m ^2. The granule dispersion | spreading process 3 was performed.

In each example shown in FIG. 4, the needle punching treatment step 6, the heating and pressing step 7, and the air cooling are performed on the mat-like intermediate molded body 17 that has been molded through the mat-like intermediate molded body forming step 5. Step 8, the preliminary cutting step 9, and the heating and pressing step 10 were performed. In the heating and pressing step 10, the distance between the press dies (spacer (distance bar) thickness) is 2.7 mm, the pressing temperature is 150 ° C., the pressing pressure is 25 kg / cm ² (about 2.45 MPa), and the pressing time is 180 seconds. The press conditions were set and executed. After performing the heating and pressing step 10, the substrate was cooled to room temperature and demolded to obtain boards of respective examples having a specific gravity of about 0.6 and a thickness of 2.7 mm.

Example 1
As the silica gel (functional powder 13), one having a particle size in the range of 10 μm or more and less than 100 μm was used.
Further, water was sprayed as the liquid 14 after the mat-like lower layer forming step 1 and after the functional granular material spraying step 3. That is, the first liquid spraying process 2 and the second liquid spraying process 4 described above were executed. At this time, the amount of water sprayed in each of the liquid spraying steps 2 and 4 was about 10 g / scale angle (90 g / m ² ).

(Example 2)
The particle diameter of the functional granular material 13 is the same as that in Example 1 above.
Moreover, it replaced with the liquid 14 (water) in the said Example 1, and sprayed the adhesive containing solution in each spraying process 2 and 4. As the pressure-sensitive adhesive-containing solution, an acrylic emulsion liquid (Acrodure (registered trademark) 958D manufactured by BASF) diluted three times with water was used.

(Comparative Example 1)
The conditions are the same as in Example 1 except that the liquid spraying steps 2 and 4 are not executed.
(Reference Example 1)
The silica gel having an average particle diameter of 2.5 mm is used, and the other conditions are the same as those in Comparative Example 1.
(Reference Example 2)
The silica gel having an average particle size of 500 μm is used, and the other conditions are the same as those in Comparative Example 1.

The following evaluation tests were performed on the boards of Examples 1 and 2, Comparative Example 1, and Reference Examples 1 and 2.
(Evaluation test) 1) Humidity adjustment performance test Each test body obtained from the board of Example 1 and Example 2, Comparative Example 1, and Reference Example 1 and Reference Example 2 was tested at a temperature of 25 ° C and a humidity of 50%. It was allowed to stand in a constant temperature and humidity atmosphere until it reached a constant weight.
Then, after leaving each test body in the constant temperature and humidity atmosphere of temperature 25 degreeC and humidity 90% for 24 hours, the weight of each test body was measured and the weight after moisture absorption was obtained.
Then, after leaving each test body in the constant temperature and humidity atmosphere of temperature 25 degreeC and humidity 50% for 24 hours, the weight of each test body was measured and the weight after moisture release was obtained.
The moisture absorption / release amount (weight change per square meter of each test specimen) obtained from the difference between the weight after moisture absorption and the weight after moisture release was judged as the humidity control performance.

As a result, except for the board of Comparative Example 1, in all the boards, the moisture absorption / release amount is 180 g / m ² or more, and the moisture absorption / release amount (130 g / m ² ) of the commercially available insulation board (9 mm thickness) Compared to this, the results were good.
On the other hand, the board of Comparative Example 1 has a large amount of silica gel falling off and scattered in the production line as a result of the powder yield measurement test described later. As a result, the amount was reduced (70 g / m ² ), and the humidity control performance could not be sufficiently exhibited.

(Evaluation test) 2) Granule yield measurement test In the board production lines in Examples 1 and 2 and Comparative Example 1, the amount of silica gel recovered relative to the amount of silica gel sprayed (dropped due to falling off, scattering, etc.) The ratio of the recovered silica gel) was calculated as the loss rate in each production line, and the powder yield rate was calculated from this loss rate.

The results are as shown in the table of FIG.
In Example 1, as described above, since the liquid spraying steps 2 and 4 were performed and water was sprayed, the silica gel adhesion to each silica gel and each fiber was improved. As a result, the recovered amount of silica gel was reduced. The yield rate was about 65% to 75%.
In Example 2, as described above, the liquid spraying steps 2 and 4 were performed and the adhesive-containing solutions were sprayed, respectively. As a result, the adhesion of silica gel to silica gels and each fiber was further improved. The amount became smaller, and the yield rate became about 80% to 90%.
On the other hand, in Comparative Example 1, since the liquid spraying steps 2 and 4 were not executed as described above, the amount of silica gel falling off and scattering in the production line increased, and the yield rate was about 30%.
In Reference Example 1 and Reference Example 2, since the added silica gel has a relatively large particle size, the change in the yield rate due to the presence or absence of execution of the liquid spraying steps 2 and 4 is not so large. Therefore, although the description of the results is omitted, in these examples also, the yield rate was improved by the execution of the liquid spraying steps 2 and 4.

(Evaluation test) 3) Surface polishing test (homogeneity)
Surface polishing (surface sanding) was performed on the boards of Examples 1 and 2 and Reference Examples 1 and 2 with the roughness of the count 180, and the entire surface was substantially uniform (substantially smooth). The number of implementations until polishing was compared. At this time, the sanding process was performed with a plate thickness of −0.3 mm (the actual polishing thickness per one time is smaller than 0.3 mm).

The results are as shown in the table of FIG.
In Example 1 and Example 2, as described above, the silica gel contained therein has a relatively small particle size, so that the distribution of silica gel in the board thickness direction and surface area direction varies. As a result, the surface became almost smooth by one sander treatment.
On the other hand, in Reference Example 1 and Reference Example 2, as described above, the silica gel contained therein has a relatively large particle size, so that the silica gel in the board thickness direction and the surface area direction has a relatively large particle size. As a result of the increase in distribution variation and the like, the reference example 1 required five or more times of the sanding process and the reference example 2 required three times of the sanding process until the surface became substantially smooth.
In addition, about the comparative example 1, since the result of the granular material yield measurement test was not favorable as mentioned above, the said surface grinding | polishing test was abbreviate | omitted.

(Evaluation test) 4) Peel strength test Peel strength according to the method prescribed in JIS A5905 (fiberboard) for each test body obtained from the boards of Examples 1 and 2 and Reference Example 2 above. A test was conducted.
The results are as shown in the table of FIG. 4, and all are standard values of peel strength defined by the JIS standard as the quality of MDF (Medium Density Fiberboard) as a building material. It became 0.3 MPa or more.
In Comparative Example 1, the peel strength test was omitted for the same reason as in the surface polishing test. Moreover, about the reference example 1, since the average particle diameter of the contained silica gel is a comparatively large particle diameter as mentioned above, the thickness difference in the plane area of a board became large, and the said peeling strength test was abbreviate | omitted. .

As mentioned above, according to the manufacturing method of the functional fiber molded object which concerns on this embodiment, the yield of the functional granular material 13 was able to be improved.
Moreover, since it is possible to effectively reduce the falling off and scattering of the functional powder 13 in the production line, it is possible to employ the functional powder 13 having a relatively small particle diameter. As a result, It was shown that even when a board with a thin plate thickness was manufactured, a homogeneous board could be manufactured as in Example 1 and Example 2.
In addition, the said Example 1 and Example 2 have shown the example manufactured using an example of the manufacturing method of the functional fiber molded object which concerns on this embodiment, respectively, and the functional fiber molded object which concerns on this embodiment is shown. As described above, various modes of the manufacturing method are possible, and the manufacturing method is not limited to these examples.

11 Plant fiber 12 Synthetic resin fiber (synthetic resin binder)
DESCRIPTION OF SYMBOLS 13 Functional granular material 14 Liquid 15 Mat-like lower layer part 17 Mat-like intermediate molded object 18 Functional fiber mat (functional fiber molded object)
19 Functional fiber board (functional fiber molding)

Claims (6)

A method for producing a functional fiber molded body containing vegetable fiber as a main material and containing a functional powder,
In a state where the surface is wetted by spraying a liquid on at least one of the vegetable fiber and the functional powder, the functional powder is added to the vegetable fiber, A method for producing a functional fiber molded body, comprising adding a functional powder and then molding to produce a functional fiber molded body. In claim 1,
The vegetable fiber is deposited to form a mat-like lower layer, and the functional powder is added by spreading the functional powder from above,
After spraying the functional powder, the plant fibers are further deposited thereon to form a mat-shaped intermediate molded body, and then the mat-shaped intermediate molded body is subjected to a needle punching process. A method for producing a functional fiber molded body, wherein plant fibers are entangled and then molded to produce a functional fiber molded body. In claim 2,
After forming the mat-like lower layer portion, before spreading the functional powder particles, the liquid is applied to the mat-like lower layer portion from above, and the functional powder particles are further dispersed. After spraying, before forming the mat-shaped intermediate molded body, the liquid is sprayed from above, and the method for producing a functional fiber molded body is characterized. In any one of Claims 1 thru | or 3,
The method for producing a functional fiber molded product, wherein the functional powder has a particle size of less than 100 μm. In any one of Claims 1 thru | or 4,
The method for producing a functional fiber molded body, wherein the liquid contains an adhesive. In any one of Claims 1 thru | or 5,
A method for producing a functional fiber molded body, wherein a synthetic resin binder is further added prior to the molding, followed by heating and pressurizing to form a board.

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