JP2003039464A - Manufacturing method for fiber molded object - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a fiber molded object including the first process for blowing a first mixture containing fibers and capable of mutually bonding the fibers in a mold cavity to obtain a fiber molded article, the second process for blowing a second mixture containing fibers and capable of mutually bonding the fibers and the same as or different from the first mixture in the mold cavity in such a state that the first molded article is housed in a mold and subjecting the same to compression molding to integrally obtain a second molded article on the first molded article and, if necessary, a process on and after the third process for blowing a mixture on and after a third mixture containing fibers and capable of mutually bonding the fibers in the mold cavity in the same way as the second process and subjecting the same to compression molding to integrally from a molded article on and after a third molded article on the second molded article. SOLUTION: The fiber molded object having a double-layered structure can be manufactured easily and certainly even if it has a complicated shape.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a fiber molding used for a cushion body used in a chair or the like, a sound absorbing body used for building materials, and the like, and particularly to a fiber molding having a multi-layer structure having a complicated shape. A method of manufacturing a body.

[0002]

2. Description of the Related Art Conventionally, the problems to be solved by the invention
The multi-layered fiber molding having a decorative surface has been manufactured by a laminating method in which the constituents of each layer are molded in separate steps and these are laminated by an adhesive or heat fusion.

However, in the manufacturing method by such a laminating method, since the constituents of each layer are manufactured in separate steps, there are problems such as an increase in the number of steps and an increase in manufacturing cost due to transportation and the like. Further, it is necessary to trim the peripheral portion of the product after stacking the components, which causes a problem of material loss. This becomes more remarkable when the laminated molded body is molded into one having a complicated shape.

Further, since the structure of each layer is already molded once, it is very difficult to obtain a fiber molded product having a multi-layer structure which is laminated and molded in a complicated uneven shape.

The present invention has been made in view of the above circumstances, and it is possible to manufacture a fiber molded body having a multi-layered structure easily, reliably, and automatically even if it has a complicated shape. The purpose is to provide a method.

[0006]

Means for Solving the Problems and Modes for Carrying Out the Invention In order to achieve the above object, the present invention provides the following method for producing a fiber molding. [Claim 1] A first step, in which a first mixture containing fibers and capable of binding fibers to each other is blown into a mold cavity to obtain a first molded article by compression molding. A second mixture, which contains the fibers in the mold cavity in the state of being housed in the mold and is the same as or different from the first mixture capable of binding the fibers together, is compression-molded onto the first molded product. The second step of obtaining a second molded product integrally with this, and the second step if necessary.
Blowing a mixture containing fibers and capable of binding fibers to each other, which is carried out in the same manner as in the step,
A method for producing a fiber molded article, comprising a third and subsequent steps of integrally forming a third and subsequent molded articles on the second molded article by compression molding. [Claim 2] The mold has at least two molds, the first mixture is blown into a mold cavity formed when these molds are joined, and compression molding is performed. The second mixture was blown into the mold cavity while holding the molded product of No. 1 and compression-molded, and if necessary, the third and subsequent mixtures were blown into the mold cavity, and compression-molding was repeated. The manufacturing method according to claim 1.

According to the manufacturing method of claim 1, unlike the method by the laminating method, it is possible to very simply manufacture a beautifully shaped multi-layered fiber molding. Further, since trimming after molding is unnecessary, loss of material can be minimized, and since the unmolded constituent material itself is filled in the mold, a laminated structure having a complicated uneven shape is manufactured. It will be possible.

According to the manufacturing method of the second aspect, the constituents of the respective layers can be simultaneously molded in one mold, the number of steps can be shortened as compared with the conventional method, and further automation is possible. Is possible.

The present invention will be described in more detail below.
The method for producing a fiber laminate of the present invention is to obtain a fiber molded product having a multilayer structure of at least two layers, preferably 2 to 4 layers, and more preferably 2 to 3 layers.

In this case, as a constituent material for forming each layer, a mixture containing fibers and capable of binding the fibers to each other is used. The mixture as a constituent material of each layer may have the same or different composition.

Here, as the fiber, a thermoplastic fiber such as polyester fiber, polypropylene fiber, polyethylene fiber, polyamide fiber,
Acrylic fibers and the like, and natural fibers such as cotton, hemp, and wool can be used. The length and diameter are appropriately selected, but the length is 10 to 100 mm, especially 20 to 70 m.
m, fineness of 0.1 to 100 denier, particularly 0.5 to 20 denier.

In addition to the fibers, foams such as polyurethane foam, rubber foam and various thermoplastic foams can be blended. These foams can be used as a granular pulverized product having an average particle size of 10 μm to 30 mm, particularly 20 μm to 10 mm.

For binding the above fibers or the like, a thermoplastic material such as polyester, polypropylene, polyamide, polyethylene or the like can be used as the binder. In this case, the thermoplastic material such as fiber or foam is the binder. Can also be used as

In the above mixture, the fiber content is 20 to 100% (weight%, the same applies hereinafter), especially 30 to
100% is preferred and the foam content is 0
It is preferably -80%, particularly 0-70%. The binder may be used in such an amount that the fiber or the fiber and the foam can be bonded.

In the present invention, first, the first mixture is blown into the cavity of the mold and compression molding is performed. FIGS. 1 and 2 show this. In FIG. 1, 1 is a mold including a lower mold 1a and an upper mold 1b. The upper mold 1b is attached to the lower mold 1a so as to be movable back and forth. By retracting, the cavity 2 is formed between the lower mold 1a and the upper mold 1b. In the figure, 3 is a blower, and 4 is a switching damper. As shown in FIG. 1, the blower 3 is operated with the upper mold 1b retracted from the lower mold 1a, and the switching damper 4 is operated to operate the first damper. The mixture is blown into the cavity 2. Then, the upper mold 1b is advanced to move the lower mold 1
The mixture 1 is compressed with a and the upper mold 1b is heated with hot air to heat the compression mixture 1 to at least partially melt the binder, thereby forming the first compression molded product A. To do.

Next, as shown in FIGS. 3 and 4, the upper mold 1b is retracted while the first molded product A is held in the lower mold 1a, the switching damper 4 is switched, and the blower 3 is operated to make the second molding. The mixture is blown into the cavity 2 and then the upper mold 1b is moved forward to compress the second mixture and the upper mold 1b is heated by hot air, whereby the first mold
A second compression molded product B of the second mixture on the molded product A of
To mold. Then, cold air is supplied to the upper mold 1b to cool the molded products A and B and take them out.

FIG. 5 shows a molded product obtained by the method shown in FIGS. 1 to 4 above.
The third and fourth molded products can be laminated by using the third and fourth mixtures by repeating the same method as in the above, and the fiber molded product manufactured by the manufacturing method of the present invention is shown in FIG. 2
The layer structure is not limited, and a multilayer structure of three layers or more can be used.

Further, in the present invention, as shown in FIGS. 1 to 4, the lower mold 1a and the upper mold 1b are not commonly used, and an upper mold having a different lower surface shape for each compression molding is used to form a cross-sectional shape of each layer. It is possible to manufacture a fiber molded body having a multi-layered structure different from each other.

The shape, thickness, density, etc. of each layer are appropriately selected, but the density of each layer is 0.02-0.5 g / c.
It can be m ³ , especially 0.03 to 0.15 g / cm ³ .

[0020]

EXAMPLES The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following examples. The fiber molded body was manufactured as follows by the method as described above. First, the upper mold is retracted with respect to the lower mold, and the mold is set to the clearance at the time of blowing, and in this state, the average particle size is 30 wt% which is made of a granular pulverized product having an apparent density of 20 kg / m ^{3 and} an average diameter of 10 mm. 40w of core-sheath composite polyester fiber with a fiber diameter of 25 μm
A mixture (mixture 1) obtained by mixing 30% by weight of polyethylene terephthalate fiber having an average fiber diameter of 20 μm with t% was filled in the mold by air flow of 600 g. After that, the upper mold is advanced with respect to the lower mold, and the mixture in the mold is moved to 20
It was compressed to a thickness of mm and hot air was blown into the mold for preliminary molding.

Again, the mold was set to the clearance at the time of blowing, and 20 wt% of the core-sheath composite polyester fiber having an average fiber diameter of 25 μm and 80 wt% of black polyethylene terephthalate fiber having an average fiber diameter of 25 μm were mixed (mixture 2 ) Was filled in the mold with an air flow of 300 g. Then, the mixture in the mold was compressed to a thickness of 20 mm, and hot air was blown into the mold for molding. Then
The mixture was cooled and solidified with cold air, and the molded body was taken out of the mold.

As a result, the shape of 17 as shown in FIG.
mm thick, foam-fiber mixture cushion layer 11 and 3mm thick 35 kg / m ^3, 2 made of layered molded gray fiber decorative layer 12 of 100 kg / m ³ was obtained.

In this case, in the conventional manufacturing method by laminating, as shown in FIG. 7, it is necessary to laminate and mold the parts 13 and 14 separately, and then to combine them, which is very time-consuming. Is.

Further, in the sheet hot pressing manufacturing method, as shown in FIG. 8, when the sheets 15 and 16 are laminated and hot pressed, the shapes of the end face and the edge of the cylindrical portion 17 are obtained as desired. Instead, the trim 18 is required.

[0025]

EFFECTS OF THE INVENTION According to the present invention, it is possible to easily and surely manufacture a fiber molding having a multi-layer structure, even if it has a complicated shape.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a state in which a first mixture is blown into a mold cavity.

FIG. 2 is an explanatory diagram of a state where the first mixture is compression-molded.

FIG. 3 is an explanatory diagram showing a state in which a second mixture is blown into a mold cavity.

FIG. 4 is an explanatory diagram showing a state in which the second mixture is compression-molded.

FIG. 5 is a cross-sectional view showing an example of a fiber molding obtained by the method of the present invention.

FIG. 6 shows a fiber molding produced according to an example,
(A) is a perspective view and (B) is a sectional view.

FIG. 7 is an explanatory diagram of a case where the fiber molding of the example is manufactured by a laminating method.

FIG. 8 is an explanatory diagram of a case where the fiber molded body of the same example is manufactured by hot pressing a sheet.

[Explanation of symbols]

1 mold 1a Lower mold 1b Upper mold 2 cavities 3 blower 4 switching damper

Claims (2)

[Claims] 1. A first step in which a first mixture containing fibers and capable of binding fibers to each other is blown into a mold cavity and compression-molded to obtain a first molded article, which is a first molded article. A second mixture, which contains the fibers in the mold cavity in the state of being housed in the mold and is the same as or different from the first mixture capable of binding the fibers together, is compression-molded onto the first molded product. A second step of obtaining a second molded product integrally with this, and if necessary, it is carried out in the same manner as in the second step, and a third mixture or later containing fibers and capable of binding fibers is blown and compressed. A method for producing a fiber molded article, comprising a third and subsequent steps of forming a third and subsequent molded articles integrally with the second molded article by molding. 2. The mold has at least two molds,
After the first mixture is blown into the mold cavity formed when these molds are joined and compression-molded,
The second mixture is blown into the mold cavity while holding the first molded product in one of the molds, and compression molding is performed.
The manufacturing method according to claim 1, further comprising blowing the third and subsequent mixtures into the mold cavity as required and repeating compression molding.