JPH04209861A - Fibrous molded article and its production - Google Patents

Abstract

PURPOSE:To obtain an exterior plate for building having excellent heat insulating properties and excellent dimensional stability irrespective of change of water content by arranging a great number of short fibrous materials in a three-dimensional state and mutually intersectionally, and fixing the intersected parts with an adhesive. CONSTITUTION:The surface of short fibrous materials such as needle-like crystal of wollastonite is coated with cement paste, further the surface of the cement paste is covered with a film material such as protein or acrylic resin, coated and a protecting film is formed to give a first fibrous processed material. Separately, the surface of the short fibrous materials is coated with a resin emulsion such as acrylic resin to give the second fibrous processed material. The same amounts of the first and the second processed materials are blended, the short fibrous materials are intersectionally arranged in a three-dimensional state and formed into a given shape. Then the formed material is pressurized by a press, the protecting film is broken at the intersecting parts, the cement paste is exposed, cured and hardened to give a fibrous molded article having dispersed voids in the interior.

Description

[Detailed description of the invention]

[00011

[Industrial Application Field] The present invention relates to a fiber molded product containing short fibrous materials such as rock wool, asbestos, glass fiber, and metal fiber, and used as exterior panels for buildings, and a method for producing the same. Regarding. [0002] [0002] Conventionally, for example, asbestos slate, which is made by mixing asbestos fibers and cement with water, molding the mixture, and curing it, has been used as an exterior board for buildings, which is representative of fiber molded products. An asbestos-cement calcium silicate plate is known, which is produced by mixing asbestos fibers, cement, and calcium silicate with water, forming the mixture into paper-forming forms, and then curing the mixture. [0003]

[Problems to be Solved by the Invention] However, in the case of the above-mentioned prior art, since the material is solid, its insulation properties are low, and furthermore, asbestos fibers, which are fibrous materials, are used as a reinforcing material, and the main body is just cement. Because of this, drying shrinkage causes expansion and contraction due to changes in moisture content, and in the case of plates in particular, warping occurs due to the difference in moisture content between the front and back sides. An object of the present invention is to provide a fiber molded article that eliminates the above-mentioned drawbacks, and a manufacturing method useful for manufacturing the same. [0004]

[Means for Solving the Problems] The characteristic structure of the fiber molded product according to the present invention is that a large number of short fibrous materials are arranged in a three-dimensionally intersecting state, and the intersecting short fibrous materials are At their intersection, they are joined by adhesive. [00051 First method for producing a fiber molded product according to the present invention
The feature is that adhesive is applied to the surface of the short fibrous material, and
A fibrous workpiece is created by coating the surface of the adhesive with a protective film that is damaged when energy is applied above a set value, and a resin emulsion is added to a large number of these fibrous workpieces and mixed, and the mixture is The process involves shaping, applying more energy to the shaped product than is set to damage the protective film, and then drying it. [00061 Second method for producing a fiber molded product according to the present invention
The feature is that, in the first feature, the protective film is one that can be damaged by applying a pressure higher than a set value, and the means for applying energy to damage the protective film is a means for pressurizing the shaped object. It is in. [0007]

[Effects of the Invention] Therefore, according to the present invention, there is provided a fiber molded product that has excellent heat insulation properties and does not expand or contract regardless of changes in moisture content, and a manufacturing method that can reliably create the same. can now be provided. [00111 [Example] Examples of the present invention are shown below. As shown in Figure 1, fiber molded products are made by arranging a large number of acicular crystals (1) of mineral crystals (wollastonite), which are an example of short fibrous materials, in a three-dimensionally intersecting state. It is constructed by connecting needle-shaped crystals (1) that intersect with each other at their intersections using cement paste (2), which is an example of an adhesive. [0012] As shown in FIG. 2, the method for producing the fiber molded article includes a first production process (A), a second production process (B), a mixing process (C), and a shaping process (D). , a pressurizing process (E), a curing process (F), and a drying process (G). (0013) As shown in FIG. 3, the first creation step (A) includes applying cement paste (2) to the surface of the needle crystal (1) and protecting the surface of the cement paste (2). This is a step of creating a first fibrous processed product (1A) by covering it with a film (3).The protective film (3) is made of protein, acrylic resin, etc., and is damaged by pressurization. The method for forming the protective film (3) is to apply a film material liquid such as a protein solution or an acrylic resin emulsion to the surface of the cement paste (2) and dry it. [0014] As shown in FIG. 4, in the second preparation step (B), a resin emulsion (4) such as acrylic is applied to the surface of the needle crystal (1) to form a second fibrous workpiece (IB). ). [0015] In the mixing step (C), equal amounts of the first fibrous workpiece (1A) and the second fibrous workpiece (IB) in which the cement paste (2) is not hardened are mixed. This is a mixing process. As a result of this mixing, the first and second fibrous workpieces (LA) and (IB) are intertwined and arranged in a three-dimensional direction. [0016] The shaping step (D) is a step of shaping the mixture from the mixing step (0) into a predetermined shape and size using a mold or the like. [0017] The pressurizing step (E) presses the shaped product obtained in the shaping step (D) using a press or the like to create contact at the intersection of the intersecting fibrous workpieces (LA) and (IB). This is a step of increasing the pressure to damage the protective film (3) of the first fibrous workpiece (1A) at the intersection. This damage to the protective film (3) exposes the cement paste (2) of the first fibrous workpiece (1A), and the needle crystals (1) of the first fibrous workpiece (1A) and the first fibrous workpiece (1A) are exposed. The first and second fibrous workpieces (LA) and (IB), which had intersected with the first fibrous workpiece (1A), will reach the intersections with the needle-like crystals (1). [0018] The curing step (F) is performed by curing the pressurized product obtained in the pressurizing step (E) under moist and heated conditions to harden the exposed cement paste (2), thereby removing the intersecting needles. This is a step of bonding the shaped crystals (1) at the intersections. In this curing step (F), the water in the resin emulsion (4) acts as curing water. [0019] The drying step (G) is a step of evaporating water in the resin emulsion (4) by drying the cured shaped article. As a result of this drying, voids are formed in the portions of the shaped article that were occupied by water in the resin emulsion. In other words, a fiber molded article with voids dispersed therein is created. [Example according to 00201C]

[00211 Another example of the present invention is shown below. 1 In the above example, needle-shaped mineral crystals were shown as the short fibrous material (1), but the short fibrous material (1) could include mineral fibers typified by mineral crystals, and mineral fibers typified by rock wool. rock fibers,
Glass fiber, metal fiber, slag fiber, ash fiber, carbon fiber,
Other examples include ceramic fibers, whiskers, etc. [0022] 2 In the above example, adhesive (2)
Although cement paste was shown as adhesive (2),
It may be made of resin. [0023] 3 In the above example, the protective film (3)
In this example, a protective film (3
) may be damaged by melting or the like when heated. In this case, the means for applying energy exceeding the set value for damaging the protective film (3) is heating means. [0024] 4 In the above embodiment, the first and second
The same amounts of the first fibrous processed material (LA) and (IB) were mixed, but their mixing ratio was different from that of the first fibrous processed material (1A).
) is determined as appropriate depending on the amount of resin emulsion (4) added. [0025] 5 In the above example, the first fibrous workpiece (1
Although the resin emulsion (4) was added to A), the resin emulsion (4) may be added alone to the first fibrous processed product (1A). [0026] Incidentally, although reference numerals are written in the claims section for convenient comparison with the drawings, the present invention is not limited to the structure of the accompanying drawings by the entry.

[Brief explanation of the drawing]

[Figure 1] Cross-sectional view of the main parts of the molded product

[Figure 2] Flowchart of creation method

[Figure 3] Cross-sectional view of the first fibrous workpiece

[Figure 4] Cross-sectional view of the second fibrous workpiece

[Explanation of symbols]

(1) Short fibrous material (2) Adhesive (3) Protective film (1A) Fibrous processed product

[Figure 2]

Claims (3)

[Claims] Claim 1: A large number of short fibrous materials (1) are arranged to intersect with each other in three dimensions, and the intersecting short fibrous materials (1) are bonded with adhesive (2) at their intersections. ) is a fiber molded product that is bonded by [Claim 2] Applying an adhesive (2) to the surface of the short fibrous material (1), and covering the surface of the adhesive (2) with a protective film (3) that is damaged by application of energy exceeding a set value. Coating to create fibrous processed products (1A), and coat these fibrous processed products (
A resin emulsion is added to a large amount of 1A), mixed, the mixture is shaped, and the shaped product is coated with the protective film (
3) A method for creating a fiber molded product in which a fiber molded product is dried after applying energy exceeding a setting level to cause damage. 3. The protective film (3) is one that can be damaged by applying a pressure higher than a set value, and the means for applying energy to damage the protective film (3) is a means for pressurizing the shaped object. A method for producing a fiber molded product according to item 2.