JP4139511B2 - Manufacturing method of fiber panel - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a fiber panel, and in particular, an open cell grid composed of a plurality of ribs, a continuous flat plate covering one opening of the grid, and a flange covering a part of the other opening. The invention relates to a method for manufacturing a fiber panel having a structure integrally formed with dense compressed fibers at a low cost.
[0002]
[Prior art]
Japanese Laid-Open Patent Publication No. 9-195440 discloses a method for manufacturing a fiber panel having an open cell lattice.
An outline of such a manufacturing method is as follows.
[0003]
First, a raw material A such as wood fiber or recycled paper is pulped with a strong stirring force to obtain a fiber-containing slurry S having a moisture concentration of about 99% (see FIG. 7A).
Subsequently, the slurry S is formed on the mold 50 including the porous carrier 51 shown in FIG. 1 and a plurality of elastomer pads 52 geometrically arranged and fixed on the plate surface of the porous carrier 51. [See FIG. 7 (b)], and dehydrated by pressing (prepress) with a flat plate from above and below the mold 50 and suction from the lower surface of the mold 50, and the slurry S has a moisture concentration of 50. % Of dehydrated cake K (see FIG. 7C).
[0004]
Thereafter, the mold 50 is conveyed to the hot press 60, and under pressure, the dehydrated cake K is heated and compression-molded by applying vertical pressure to the mold 50 (see FIG. 8 (a)). The molded product X is about%.
After the molding is completed, the molded product X is taken out from the hot press 60 together with the mold 50, and the molded product X is removed from the mold 50 (see FIG. 8B).
[0005]
Through the steps described above, an open cell lattice 71 composed of a plurality of ribs as shown in FIG. 2, a continuous flat plate 72 covering one opening of the lattice 71, and a part of the other opening A fiber panel 70 having a structure in which a covering flange 73 is integrally formed with dense compressed fibers can be manufactured. The fiber panel 70 is a lightweight and high-strength panel, such as a housing member, joinery or furniture. This is a product that can be used effectively for recycling resources such as waste paper.
[0006]
[Problems to be solved by the invention]
However, the fiber panel 70 obtained by the above manufacturing method has a problem that the power consumption during the manufacturing is large and the manufacturing cost is high.
This is because the raw fiber placed on the mold 50 has a high water content of about 99%, and the raw material fiber having a high water content is subjected to processes such as pre-pressing, heat compression molding and the like, and a molded product X having a water concentration of about 8%. Although it is clear that it was caused by dehydration using electric energy until the water content of the raw material fibers to be placed on the mold 50 was lowered, the fluidity of the raw material fibers deteriorated. In addition, since the filling of the raw material fibers between the plurality of elastomer pads 52 constituting the mold 50 becomes insufficient, and the quality such as appearance and strength of the obtained molded product X is deteriorated, hitting the mold has been conventionally performed. It was difficult to reduce the moisture content of the raw fiber from the time of installation.
[0007]
The present invention has been made in view of the problems of the above-described conventional method for manufacturing a fiber panel having an open cell lattice, and its purpose is to greatly increase the moisture content of raw material fibers to be placed on a formwork. An object of the present invention is to provide a method for manufacturing a fiber panel having an open cell lattice at a low cost by reducing power consumption for manufacturing a product.
[0008]
[Means for Solving the Problems]
As a result of repeated tests and researches to achieve the above-described object, the present inventors have confirmed that the flowability of the raw material fibers between the plurality of elastomer pads constituting the mold is surely fluid. Although it is better to use a slurry material with a high moisture content, at least the fluidity of the material fiber laminated above the elastomer pad is not required, and it is possible to use a material fiber with a low moisture content. In addition, even in the raw fiber filled between the elastomer pads, if the operation of pushing between the elastomer pads by mechanical pressing force is performed, the filling property can be improved even with the raw fiber having a considerably low water content. Knowledge was obtained and the present invention was completed.
[0009]
That is, the first aspect of the present invention uses a mold frame composed of a porous carrier and a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the porous carrier, and is constituted by a plurality of ribs. A fiber panel having a structure in which an open cell lattice, a continuous flat plate covering one opening of the lattice, and a flange covering a part of the other opening are integrally formed of dense compressed fibers In this method, a raw material fiber having a moisture content of 50% or more is first placed between elastomer pads constituting the mold, and then a raw material fiber having a moisture content lower than that of the raw material fiber is placed thereon. It was set as the manufacturing method of the fiber panel including the process of placing the fiber on the formwork, and the process of heat-compressing the raw material fiber placed on the formwork.
[0010]
A second aspect of the present invention uses a mold frame composed of a porous carrier and a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the porous carrier, and is constituted by a plurality of ribs. A fiber panel having a structure in which an open cell lattice, a continuous flat plate covering one opening of the lattice, and a flange covering a part of the other opening are integrally formed of dense compressed fibers a method of, first, water content 35% or more of the raw material fibers between elastomeric pad constituting the mold to Da設, after pushed between elastomeric pad by mechanical pressing force of the raw material fibers, further wherein in its upper A two-stage raw fiber placement process for placing raw fiber having a moisture content equivalent to that of the raw fiber or a raw fiber having a lower moisture content than the raw fiber, and placed on the mold Heating raw fiber It was method for producing a fiber panel comprising the step of condensation forming.
[0011]
According to the above-described method for manufacturing a fiber panel according to the present invention, the total moisture content of the raw material fibers to be placed on the mold is greatly reduced without hindering the filling property of the raw material fibers between the elastomer pads. can do.
That is, in the first invention, between the elastomer pads where the gap is narrow and the raw fiber filling is poor, the raw material fiber having a water content of 50% or more, for example, the raw material adjusted to a water content of about 99% as in the prior art. Since a fiber is placed and a raw material fiber having a moisture content lower than that of the raw material fiber, for example, a raw material fiber adjusted to a moisture content of about 10% is placed thereabove, in the second invention, Raw material fibers placed between elastomer pads with poor raw fiber filling properties, for example, raw material fibers with a moisture content of about 35% are pushed between the elastomer pads by mechanical pressing force, and further above the raw material fibers, for example, moisture content Since the raw material fibers having a rate of about 10% were to be placed, in any of the above-described inventions, the filling property of the raw material fibers between the elastomer pads was good, and on the formwork Total specific moisture content of the raw fiber to set can be greatly reduced.
In the first invention, the moisture content of the raw material fiber to be placed first needs to be 50% or more. This is because the raw material fiber having a moisture content of less than 50% is insufficiently filled even if means called suction from the lower surface of the mold is used. In this case, according to the second invention A means may be adopted.
[0012]
Here, in the present invention, the process of heat compression molding the raw material fibers placed on the mold in two stages is a hot press in a state heated by a heater or a heating fluid as in the prior art. However, under a press with a flat plate from above and below the formwork, a high frequency voltage is applied between the press flat plates to heat the raw material fibers by high frequency dielectric heating. Is preferred.
This is because the mold used in the present invention has an elastomer pad made of an elastic material such as silicon rubber having a low thermal conductivity as its constituent member, so that a heated flat plate expecting conventional conductive heat transfer It is preferable to cause dielectric heating of the raw material fiber itself by applying a high frequency voltage rather than heat compression molding by pressing, because efficient heating is possible.
[0013]
The raw material fibers referred to in the present invention include natural fibers such as wood fibers and cellulose fibers, synthetic fibers such as plastic fibers, rock wool and glass fibers, and mixed fibers thereof.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of a manufacturing method of a fiber panel concerning the above-mentioned present invention is described in detail based on a drawing.
[0015]
The molds used in the present invention can be the same as the conventional ones.
That is, as shown in FIG. 1, the mold 50 is composed of a porous carrier 51 and a plurality of elastomer pads 52 geometrically arranged and fixed on the plate surface.
As shown in FIG. 6, each of the elastomer pads 52 of the mold 50 expands in parallel to the carrier 51 from the center toward the outside when the pad is compressed, and is filled between the pads. At the same time as the fibers are compressed, the fibers are of a predetermined size and shape so that the fibers located above the pad and below the enlarged pad can also be compressed.
[0016]
The porous carrier 51 has a structure in which a plurality of through holes are formed in a normal rectangular metal plate, and a belt-like press stopper is provided on the peripheral plate surface as a reinforcement as shown in FIG. 53 is attached. The porous carrier 51 may be constituted by a single plate or may be constituted by overlapping a plurality of plates.
[0017]
The elastomer pad 52 is formed of a material having sufficient elasticity. For example, the elastomer pad 52 can be formed using various synthetic rubbers including silicon rubber, chloroprene rubber, etc. It is particularly excellent when considering elasticity.
Then, the elastomer pad 52 is formed into a trapezoidal body having a hexagonal cross section as shown in an enlarged manner in FIG. 1, so that the cell lattice 71 of the manufactured fiber panel 70 is formed into a hexagonal shape as shown in FIG. It becomes possible.
[0018]
In the manufacturing method according to the present invention, first, the raw fiber F is placed on the mold 50. As the raw fiber F, natural fibers such as wood fibers and cellulose fibers, plastic fibers, rock wool, glass fibers and other synthetic fibers, and mixed fibers thereof can be used. A material mainly composed of cellulose fibers is preferable, and the raw material fibers F mainly composed of cellulose fibers were used in the following embodiments. However, the present invention is not limited to this.
The raw fiber F placing process is divided into two stages in the present invention.
That is, the process of placing the raw material fiber F between the elastomer pads 52 constituting the mold 50 in which the gap is narrow and the filling of the raw material fiber F is difficult, and the process of placing the raw material fiber F thereabove. It is a stage. In addition, it is preferable that the filling amount of the raw fiber F in the first placement is 40 to 50% of the whole.
As embodiment of the placement process of the said raw material fiber F, there exists a form shown in FIG.3 and FIG.4.
[0019]
First, those shown in Figure 3, provides two kinds of the raw material fibers F _H and F _L having different water content, the gap is narrow, high filling of the raw material fibers having the moisture content to between poor elastomeric pad 52 material fibers _{F H,} for example, the raw fibers is adjusted to a moisture content 50-80% by pouring [refer to FIG. 3 (a)], then lower material fiber moisture content thereabove _{F L,} for example, water content 10% The raw material fiber adjusted to the extent is placed (see FIG. 3B).
[0020]
Upon for pouring a high water content material fiber F _H between the elastomeric pad 52 pouring conventional raw fibers is adjusted to a water content of about 99% in the same manner on the mold 50 only by the action of gravity may be one, but pouring the raw material fibers F _H, which is adjusted to a moisture content 50-80% on the mold 50 while sucking from the lower surface of the mold 50 as shown in FIG. 3 (a) When it, together with a sufficiently filled between elastomeric pad 52 is mold raw material fibers F _H, it is possible to reduce the water content, preferably to a power required in a post process can be further reduced.
[0021]
Here, according to the test conducted by the present inventors, if the raw material fiber is adjusted to a water content of 50% or more, it is sucked at about −650 mmHg as necessary when it is placed between the elastomer pads 52. Then, the filling is performed satisfactorily. For example, raw material fibers adjusted to a moisture content of about 65% are placed between the elastomer pads 52, and then the moisture content of the raw material fibers to be placed thereon is about 10%. If so, the total moisture content of the raw fiber F cast on the mold 50 was about 40%.
[0022]
Also, those other embodiment shown in FIG. 4, after the material fiber F _M into between the elastomeric pad 52 has Da設[refer to FIG. 4 (a)], the raw material fibers F _M using reverse type 80 pressed from above pushing the between elastomeric pad 52 [refer to FIG. 4 (b)], in which subsequently the further material fiber F _M thereabove to Da設[refer to FIG. 4 (c)].
[0023]
In pouring this form, the material fiber of pouring material fiber and thereabove to pouring into between elastomeric pad 52 as shown in FIG. 4, the raw material fibers F _M that are both adjusted to the same moisture content For example, raw material fibers adjusted to a moisture content of about 35% may be used, but two types of raw material fibers F _H and F _L having different moisture contents are prepared as in the embodiment shown in FIG. In addition, a raw fiber F _H having a high moisture content, for example, a raw fiber adjusted to a moisture content of 40 to 60% is used between the elastomer pads 52, and a raw fiber F _L having a low moisture content, for example, It is preferable to use raw material fibers adjusted to a water content of about 10% because the total water content of the raw material fibers F placed on the mold 50 can be further reduced.
[0024]
Here, according to the test conducted by the present inventors, if the raw material fiber is adjusted to a moisture content of about 40%, the raw fiber is placed between the elastomer pads 52, and then the raw fiber is used by using the reverse mold 80. If it presses with about 0.5 kgf / cm < ² > from the upper part, filling will be performed satisfactorily, and if the moisture content of the raw material fiber to be placed thereafter is about 10%, it will be cast on the mold 50 The total moisture content of the raw fiber F was about 22%.
[0025]
After the step of placing the raw material fibers F on the mold 50 in the above two steps, the raw fibers F on the mold 50 are heat-compressed to obtain a molded product X having a moisture concentration of 10% or less.
In the heat compression molding process of the raw fiber F, a hot press is used in the same manner as in the prior art, and a flat plate heated by a heater or a heating fluid is pressed from above and below the mold 50. However, as shown in FIG. 5, a high frequency voltage is applied between the flat plates for pressing under the pressing of the flat plate from above and below the mold 50, and the raw fiber F itself is heated by high frequency dielectric heating. It is preferable to do.
This is because the formwork used in the present invention is composed of the elastomer pad 52 made of an elastic material such as silicon rubber having a low thermal conductivity as described above, so that it is heated to expect conduction heat transfer. It is preferable to cause dielectric heating of the raw fiber F itself by applying a high-frequency voltage, rather than heat compression molding using a flat plate press, because efficient heating is possible.
[0026]
Further, when the raw material fiber F is subjected to high frequency dielectric heating, as shown in FIG. 5, if the evaporated liquid is sucked and removed by sucking from above and below the mold 50, insulation between flat plates is obtained. The degree of heating increases, enabling efficient dielectric heating of the raw material fiber F, and as shown in the figure, the press surface of the press platen is heated to about 120 to 160 ° C. by a heater or a heating medium. Further, when the heating of the raw material fiber F by conductive heat transfer from above and below the mold 50 is used in combination, drying unevenness of the raw material fiber F due to nonuniform application of high-frequency power can be eliminated. Is more preferable.
[0027]
In the heat compression molding process of the raw fiber F on the mold 50 described above, the elastomer pad 52 constituting the mold 50 is deformed flat by the compressive force of the press as shown in FIG. 6, and is filled between the pads. The raw fiber F is compressed not only in a direction perpendicular to the mold but also in a parallel direction, and formed into a fiber panel having a dense open cell lattice.
[0028]
Here, the test conducted by the present inventors, the compression pressure applied to the material fiber F on the mold 50 by press platen in the heat compression molding step is generally a 10~12kgf / cm ² or so, Moreover, the high frequency voltage applied between the flat plates for pressing is about 22% of the total moisture content on the mold 50 when a high frequency voltage of 13.56 MHz and a voltage of 200 V is applied for about 50 to 100 seconds. The raw material fiber F thus obtained could be formed into a molded product X having a moisture concentration of 10% or less.
[0029]
Further, according to the tests conducted by the present inventors, raw material fibers adjusted to about 99% as in the prior art are used, the raw material fibers are dehydrated to about 50% by pre-pressing, and then the raw material fibers are used. The amount of electric power when F was hot-compressed by hot pressing was about 10 kWh per 1 kg of the molded product. However, as in the present invention, the placement of the raw material fibers on the mold is between the elastomer pads and above it. When the total moisture content of the raw material fibers F on the mold is about 22%, when the raw material fibers F are hot-compressed by hot pressing as before without pre-pressing It has been confirmed that the amount of electricity can be greatly reduced to about 3 kWh per 1 kg of the molded product.
[0030]
As mentioned above, although embodiment of the manufacturing method of the fiber panel concerning this invention was described, this invention is not limited to above-mentioned embodiment, In the range of the technical idea of this invention, various Variations and changes are possible.
[0031]
For example, in the above-described embodiment, a batch type is used as the mold 50, but the porous carrier constituting the mold 50 is belt-shaped or wheel-shaped so It is good also as what was moved so that a process might be received continuously.
[0032]
Further, in the above embodiment, a description has been given of the case where the so-called prepress dehydration process is omitted. However, a prepress process may be provided as in the prior art, and at that time, a DC voltage is applied between the flat plates for pressing. The raw fiber F placed on the mold 50 may be electroosmotic dehydrated.
[0033]
【The invention's effect】
As described above, the fiber panel manufacturing method according to the present invention has the greatest feature in that the placement of the raw material fiber on the mold is divided into two stages, that is, between the elastomer pads and above. The total moisture content of the raw material fibers placed on the mold can be greatly reduced without hindering the filling property of the raw material fibers between the pads. As a result, the power consumption in the subsequent heat compression molding process, etc. The amount can be greatly reduced, and a fiber panel having an open cell lattice can be manufactured at low cost.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an embodiment of a mold used for manufacturing a fiber panel.
FIG. 2 is a perspective view showing a fiber panel that is a molded article.
FIG. 3 is a view showing an embodiment of a raw fiber placing process during a fiber panel manufacturing process according to the present invention, in which (a) shows a raw fiber F _H having a high water content as a formwork. state of pouring into between the elastomer pad, (b) is a conceptual diagram respectively indicated a state of pouring a low material fiber F _L water content to above it.
During the manufacturing process of the fiber panel according to the present invention; FIG is a conceptual diagram showing another embodiment of the more striking設工of material fiber, (a) an elastomeric pad is mold the material fiber F _M state of pouring into between, (b) a state of pressing from above by using a reverse-type raw material fibers F _M that is pouring into between the elastomer pad, (c) further material fiber to push further had the material fiber F _M the F _M is a conceptual diagram respectively indicated a state of pouring.
FIG. 5 is a conceptual diagram showing an embodiment of a heat compression molding process of raw fiber during the fiber panel manufacturing process according to the present invention.
FIG. 6 is a cross-sectional view showing a state of a raw fiber during a heat compression molding process.
7A and 7B are diagrams showing a conventional fiber panel manufacturing process, where FIG. 7A is a process for manufacturing a raw slurry, FIG. 7B is a process for placing a raw fiber on a mold, and FIG. 7C is a raw material. It is the figure which each showed the dehydration process of the fiber.
FIGS. 8A and 8B are diagrams showing a conventional fiber panel manufacturing process, where FIG. 8A shows a raw fiber heating compression molding process, and FIG. 8B shows a product peeling process from a formwork. .

Claims (3)

An open cell lattice comprising a plurality of ribs using a formwork composed of a porous carrier and a plurality of elastomer pads geometrically arranged and fixed on a plate surface of the porous carrier, and the lattice In the method of manufacturing a fiber panel having a structure in which a continuous flat plate covering one of the openings and a flange covering a part of the other opening are integrally formed of dense compressed fibers, the above-mentioned frame is formed. First, a raw material fiber having a moisture content of 50% or more is placed between the elastomer pads, and then a raw material fiber having a moisture content lower than that of the raw material fiber is placed thereon, and then a two-stage raw material fiber is placed on the formwork. The manufacturing method of a fiber panel characterized by including the process and the process of carrying out the heat compression molding of the raw material fiber casted on the said formwork. An open cell lattice comprising a plurality of ribs using a formwork composed of a porous carrier and a plurality of elastomer pads geometrically arranged and fixed on a plate surface of the porous carrier, and the lattice In the method of manufacturing a fiber panel having a structure in which a continuous flat plate covering one of the openings and a flange covering a part of the other opening are integrally formed of dense compressed fibers, the above-mentioned form is formed. First, a raw material fiber having a moisture content of 35% or more is placed between the elastomer pads, and the raw material fiber is pushed between the elastomer pads by a mechanical pressing force. A step of placing a raw material fiber having a moisture content lower than that of the raw material fiber or the raw material fiber onto the mold, and a step of heat-compressing the raw material fiber placed on the mold Including Wherein the method of manufacturing a fiber panel. The process of heat-compressing the raw material fibers on the above-mentioned formwork is a high-frequency dielectric heating of the raw-material fibers by applying a high-frequency voltage between the pressing flats under a press with a flat plate from above and below the formwork. The manufacturing method of the fiber panel of Claim 1 or 2 characterized by the above-mentioned.

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