JP2003276005A - Molded fibrous panel having compressed skin structure, treated with lignophenolic derivative - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a means for improving the bending strength and water resistance of a molded fibrous panel having a compressed skin structure which is molded of cellulose fibers and has a honeycomb structure. <P>SOLUTION: The molded fibrous panel having the compressed structure comprises a fibrous part of the compressed skin structure being continuous substantially, a fibrous grating comprising a plurality of opening cells constituted of a plurality of ribs having a thickness parallel to the face of the grating and a height regulating the thickness of the grating, and a fibrous flange part extending to a part of the surface area of each cell of the grating located on the opposite side of the compressed skin fibrous part. The compressed skin fibrous part, the fibrous grating part and the fibrous flange part are molded integrally. By treating this molded fibrous panel having the compressed structure which has the open cell grating, with a lignophenolic derivative, the molded fibrous panel having the compressed structure is obtained. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded compressed skin structure fiber panel whose performance is modified by treatment with a lignophenol derivative and a method for producing the same. In particular, the present invention relates to a molded compressed skin fiber panel having an internal open cell lattice, the performance of which is modified by treatment with a lignophenol derivative, and a method for producing the same.

[0002]

2. Description of the Related Art Global warming, ozone layer depletion, tropical rainforest reduction, global environmental issues such as acid rain, and dioxins generated from cleaning plants, industrial waste treatment plants, and other waste disposal sites Environmental problems in familiar areas and districts are largely due to deforestation due to increased use of wood or incineration of chemical products. Under such circumstances, it is desired to develop recyclable products that replace wood and chemical products. There are many recyclable materials even now, but few are easily available, completely pollution-free and easy to recycle.

Cellulose fiber is known as one of the materials that is easily available, completely pollution-free and easily recycled. Paper retains its shape by hydrogen bonding between cellulose and hemicellulose. The paper used as it is is very easy to recycle, but the paper is subjected to various processing depending on the purpose of use, but in particular, it is often improved in strength and water resistance. These treatments are often performed with chemically synthesized substances, but it is very difficult to reuse them after that and they are currently disposed of.

[0004] Further, the fiber panel having a molded compression skin structure described in Japanese Patent No. 3048529 has a honeycomb structure in a shape molded from a cellulosic fiber and has a very advantageous characteristic as a material replacing wood. (Figure 1). In addition, this molded compression-hull structure fiber panel has characteristics that the apparent density is 0.24, which is very light, and the bending specific strength is very strong, in comparison with building material panels and the like, while in terms of bending strength and water resistance. There was a problem that it was weak. Various processes such as chemically synthesized products are known as processes for improving the bending strength and water resistance, but all of them are extremely difficult to recycle.

[0005]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems of the prior art.
That is, it is an object of the present invention to provide means for improving the bending strength and water resistance of a molded compressed outer structure fiber panel having a honeycomb structure formed of a cellulosic fiber. Another object of the present invention is to provide a molded compressed outer structure fiber panel that can be easily recycled while improving bending strength and water resistance.

[0006]

Means for Solving the Problems As a result of intensive studies for solving the above-mentioned problems, the present inventor has found that treating a molded compressed structure fiber panel with a lignophenol derivative can improve bending strength and water resistance. I found that I could do it. The lignophenol derivative used in the present invention is, for example, JP-A-2-233701 or JP-A-9-27.
8904 publication, or PCT / JP97 / 03240
It has been found for the first time that the lignophenol derivative is obtained by the method described in Japanese Patent Publication No. 1994-010, and the strength and water resistance of the panel are improved by impregnating the molded and compressed structural fiber panel.

In the PCT / JP97 / 03240 specification, a high density cellulose fiber mat such as a rectangular parallelepiped or a cube is impregnated with a binder such as lignophenol, but a high density molded body is impregnated with the binder. However, there is a problem in that it takes time and a large amount of binder is used to evaporate and attach the solvent.

The molded and compressed structure fiber panel used as a mat in the present invention has a density of 0.24, PCT / JP97 /
Since the density of the mat used in the experiment of No. 03240 is 1/4, the impregnation and drying time of the binder can be greatly shortened, and the amount of the binder used can be small.

Further, in the present invention, PC is used as a binder.
The lignin derivative described in T / JP97 / 03240 can also be used, and the binder material or the aryl coumaran body can be efficiently separated and extracted from the molded body in a reusable manner. Further, by this treatment, the cellulose yarn fiber which is a molding base material is also classified as reusable at the same time, and a triangular recycled molded body is manufactured.

That is, according to the present invention, a fiber portion having a substantially continuous compressed outer structure and a thickness parallel to the plane of the lattice are provided,
A fiber lattice including a plurality of open cells constituted by a plurality of ribs having a height that defines the thickness of the lattice and extending to a part of the surface area of each cell of the lattice opposite to the compressed skin fiber portion. A molded compressed structural fiber panel having an open cell lattice, wherein the compressed skin fiber portion, the fiber lattice portion, and the fiber flange portion are integrally molded, including a fiber flange portion that is treated with a lignophenol derivative. A molded and compressed structural fiber panel is thereby obtained.

Preferably, the lignophenol derivative is
(1) A lignophenol derivative obtained by adding an acid to a lignocellulosic material to which a phenol derivative has been added and mixing to separate the lignocellulosic material into a lignophenol derivative and a carbohydrate, and (2) the lignophenol. At least one lignophenol derivative selected from the alkali-treated derivative of the derivative, or (3) the above-mentioned lignophenol derivative or the derivative obtained by protecting the hydroxyl group in the alkali-treated derivative.

Preferably, the amount of the lignophenol derivative impregnated is 1 to 3 with respect to the weight of the molded and compressed structural fiber panel.
0%, and more preferably 5 to 20%. Preferably, a lignophenol derivative produced by adding a phenol optionally having one or more substituents to a lignocellulosic material is used.

According to another aspect of the present invention, there is a substantially continuous compressed skin structure fiber portion and a height having a thickness parallel to the plane of the lattice and defining the thickness of the lattice. A compressed outer skin comprising a fiber lattice including a plurality of open cells formed by a plurality of ribs and a fiber flange portion extending to a part of a surface region of each cell of the lattice opposite to the compressed outer sheath fiber portion. Molded compressed structure fiber panel of the present invention, comprising a step of treating a molded compressed structure fiber panel having an open cell grid, in which a fiber part, the fiber lattice part and the fiber flange part are integrally molded, with a lignophenol derivative. A method of manufacturing the same is provided.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below. The molded and compressed structural fiber panel of the present invention is obtained by treating the molded and compressed structural fiber panel with a lignophenol derivative.

The molded compressed structural fiber panel used in the present invention has a substantially continuous compressed outer structural fiber portion and a thickness parallel to the plane of the lattice, and a height defining the thickness of the lattice. And a fiber flange portion including a plurality of open cells constituted by a plurality of ribs having a plurality of ribs and a fiber flange portion extending to a part of the surface area of each cell of the lattice opposite to the compressed outer fiber portion, It is characterized by having an open cell lattice in which the outer fiber portion, the fiber lattice portion, and the fiber flange portion are integrally formed.

Molded and Compressed Structure Fiber Panel The most preferable molded and compressed structure fiber panel used in the present invention is Japanese Patent Application No. 8-245574 (Patent No. 3048).
529). Below is an overview of this panel.

Soft wood and hard wood have been used as structural materials for many years in the construction industry because they have suitable strength properties, are relatively inexpensive, and are easy to manufacture and process. However, as the cost of wood increases, substitutes such as rigid boards are more widely used due to their cheapness. Rigid board usually consists of cellulose fibers, water and a binder such as latex, starch paste or ureaformaldehyde. However, all these substitutes also have the problem of reduced raw materials, low strength-to-weight ratio or the use of unfavorable solvents and binders in their production or processing.

For many years, corrugated board has been used as the basic lightweight material for packaging and for other light duty applications. Corrugated board is made from flat fiberboard material. A single sheet is corrugated to form a core or corrugated media. This requires independent work. Next, an adhesive is applied to one or both nodes of the corrugated core, and one or two flat plates are attached to each. The shape of the core is retained by this bonding. However, corrugated panels are relatively weak and cannot be used for structural applications.

It is also known to manufacture pulp molded articles such as egg paper containers, flower pots and baskets. These products are made using rigid molds. This mold is often semi-porous and covered with screening material. Suction from the back of the mold causes a flow through the screen and the mold, with the fibers forming a uniform mat on the screen. On the mat formed on the rigid mold, press the inverted rigid mold that fits on this mold,
Consolidate the mat. This causes the mat to set between the two mating molds. The direction of this compaction force is
Perpendicular to the mat. However, such products lack strength as structural materials.

It is known in the prior art to manufacture a compressed skin structural panel for use as a structural material in order to increase the strength of the formed panel. Such panels are considered advantageous due to their high strength to weight ratio. However, high manufacturing costs limit commercial use of these products to expensive valuables.

Previously, in such panels, a skin layer was applied to an internal grid, commonly called a "honeycomb,"
It was formed in layers. These honeycombs are usually made by joining flat sheets or strips of paper or paper-like material by gluing them at regularly spaced points. The braid is pressed, allowing time for the adhesive to cure. A second skin is often affixed as well, and the one thus formed is cut to the required dimensions.

Recently, the basic constituent parts of the compressed skin structure panel are molded from various fiber materials. Two such components are glued together to complete the panel. Reference is made, for example, to U.S. Pat. No. 4,702,870. The panel constructed in this way is advantageous over the prior art.
That is, it is excellent in flexibility in that many gluing and other manufacturing steps can be eliminated and many different types of open cell grids can be manufactured.

However, in order to finish the panel manufactured according to this conventional technique, at least one gluing step and the work associated therewith are required to bond the two component parts together, which increases the cost. Further, the nature of the panel having two layers defines a substantially constant limit on the thickness and weight per unit surface area of the finished panel. Moreover, the surface area available for the adhesive contact surface during laminating is generally quite small, and any slight misalignment of the two layers will substantially weaken the adhesive strength of the adhesive. According to the teachings of the prior art, this problem can only be solved by increasing the rib thickness of the inner grid. However, this approach results in a significant increase in panel weight without a corresponding increase in strength.

For this reason, there is a demand for a molded compressed skin structure fiber panel having an increased surface area that can be used as an adhesive contact surface between layered panels, and further, it can be manufactured in one step,
It has been desired to provide a shaped, compressed skin structure fiber panel having a second skin that covers a substantial portion of the interior open cell lattice. Furthermore, it was considered desirable to be able to manufacture such panels from recycled fibers such as cellulosic fibers.

A conventional method of forming a compressed skin structure panel is described in US Pat. Nos. 4,702,870 and 4,753.
713, No. 5,198,236, No. 5,277,8
54 and 5,314,654, as well as PCT Publication W092 / 21499.

In the above-mentioned Japanese Patent Application No. 8-245574, there is provided a molded compressed skin structure fiber panel having an internal opening cell lattice which is manufactured at a low cost and by an excellent method, and a manufacturing method thereof. In the present invention, such a molded compressed outer structure fiber panel can be used. The fibers used in the panel can be obtained from natural fibers such as cellulose, or various plastics, synthetic materials such as fiberglass, but in the present invention, for that purpose, generally, the types of fibers originally discarded are used. Natural fibers such as cellulose are used. In the present invention, it is preferable to use paper made of recycled resources among such raw materials.

As a first aspect, the molded compression-hull structure fiber panel used in the present invention has a grid including a plurality of open cells constituted by a plurality of ribs, and a continuous flat plate covering one opening of the grid. And a flange that covers a part of the other opening, and the lattice, the flat plate, and the flange are integrally molded, and are made of compressed fibers. The panel has an integrally formed flange on the opposite side of the integrally formed grid that extends over at least a portion of the surface area of each cell of the grid. This flange increases the area that can be used as an adhesive surface when two panels are attached, simplifies the manufacturing process, and improves the strength of the final product.

In another aspect, the molded compressed skin fiber panel is a monolithic monolithic panel having a compressed skin layer on both sides of the open cell lattice. In this aspect,
The integrally formed flange extends over a substantial portion of the surface area of each cell of the lattice to form a second compressed skin fiber portion. The panel with this second skin has the advantage that it can be manufactured in substantially one step.

The molded compressed skin fiber panel also comprises the steps of arranging the porous carrier means, arranging a plurality of elastomer pads on the carrier means, wherein each of the pads is compressed by the pad. The carrier having a predetermined size and shape so as to apply pressure to a portion of the carrier surrounding the pad, and positioning the pads on the carrier in a predetermined spaced relationship with each other; and covering the pad. A step of depositing fibers on the carrier so as to fill the space between the pads, and a means of depositing the fibers is a carrier fluid method of discharging a carrier fluid through the carrier and the deposited fibers. By applying a pressure perpendicular to the carrier to the end of the pad remote from the carrier, Compressing the deposited fibers in both running directions, when the pressure is applied, the pad expands parallel to the carrier from its center outwards to compress the fibers between the pads. At the same time, it is manufactured by a method for manufacturing a molded compressed outer structure fiber panel having an open cell lattice, in which fibers located above the pad and below the expanded pad are compressed and consolidated together.

The panel used in the present invention and the method for producing the same can be produced or carried out by using an apparatus for producing a fiber panel having a molded compressed skin structure as described below.
The device has a porous carrier and a plurality of elastomeric pads disposed thereon, each of the pads having a predetermined capacity to compress the deposited fibers under the pad as the pad is compressed. Has size and shape. The apparatus comprises means for positioning the pads in a predetermined spaced relationship to each other on the carrier, means for depositing fibers on the carrier to cover and fill the spaces between and above the pads, and the carrier of the pads. Means for consolidating the deposited fibers in both directions, perpendicular and parallel to the carrier, by applying a pressure perpendicular to the carrier to the remote end. This causes the pad to be spread out parallel to the carrier, compressing the fibers between the pads and consolidating the fibers located above and below the compressed pad.

In the apparatus used to produce the molded, compressed skin fiber panel used in the present invention, the bond between the pad and the carrier is such that the size of the base of the pad is such that the force applied in the direction perpendicular to the carrier. Even more preferably, it is originally performed so as not to spread substantially in the horizontal direction. If the pad is flexible enough, simply applying vertical pressure to the carrier will increase the mechanical friction between the carrier and the pad, and Directional expansion is hindered to some extent. However, as a more reliable method, for example, the unevenness on the carrier and the corresponding part or the whole surface of the bottom surface of the elastic pad are engaged with each other to prevent the base portion of the pad from spreading in the horizontal direction by a mechanical force, or It is possible to adopt a method in which the bottom portion and the carrier are fixed to each other by welding or bonding the bottom portion of the pad over a substantial portion or the entire surface of the bottom surface of the pad to integrate them.

The elastomeric pad not only establishes the initial shape of the lattice, but also determines its compressed state. These pads have a predetermined shape and size and are arranged in a predetermined mutual relationship on the carrier. The size and shape of these pads and the method of choice of spacing on the carrier determine the properties of the final product. This will become more apparent from the detailed description below.

With respect to the molded compressed skinned fiber panel used in the present invention, there is provided a method of making a molded compressed skinned fiber panel further using a carrier fluid containing fibers. The fibers are deposited on and between the pads by pouring a carrier fluid containing the fibers. After the fibers are deposited, pressure is applied from above the pad to compact the grid. When this pressure is applied, the pad contracts in the direction of the pressing force, but at the same time it expands in a direction perpendicular to the direction of this pressing force, reducing the space between the padded fibers. The pad is configured to consolidate the deposited fibers in the space near the carrier during compression of the pad. Thus, the deposited fibers between the pads are consolidated both vertically and horizontally in the open cell grid, and the fibers on top of the pad are consolidated to form a first molded skin integral with the grid,
Also, in the area around the base of the compressed pad, the fibers are consolidated to form a flange integrally formed with the lattice. The flange covers at least a portion of the surface area of each cell.

In the present invention, there is used a pallet which includes at least a top plate made of the above-mentioned molded compression skin structure fiber panel and a leg part made of a paper tube, and the leg part is fixed to the top plate. You can also The paper tube used for the legs is an extremely rigid paper tube that is wound multiple times while applying an adhesive to the paper tube base paper, and is preferably used to wind the paper base paper such as newsprint and corrugated cardboard paper. The cylindrical paper tube used is used. This paper tube is excellent as a recycling resource because it retains its basic strength and outer shape even after removing the base paper such as newspaper and corrugated board, and can be obtained easily in large quantities at low cost. Outer diameter is 100 to 125m
m, and the paper thickness is preferably 10 mm to 20 mm.

In order to fix the paper tube to the top plate, for example, adhesion with an adhesive is suitable. As an adhesive,
Vinyl acetate emulsion-based adhesives [for example, SH20 (trade name) manufactured by Konishi Co., Ltd.] and modified vinyl acetate emulsion-based adhesives [for example, CH18 (trade name) manufactured by Konishi Co., Ltd.] ] Can be mentioned. As a material used when high adhesion performance such as water resistance is required, an aqueous polymer isocyanate-based adhesive [for example, CU-1 (trade name) manufactured by Konishi Co., Ltd.] can be mentioned. As an adhesive that adheres in a short time, a water-based differential coating adhesive [eg, HB1 manufactured by Konishi Co., Ltd.
0 (trade name)], ethylene vinyl acetate-based hot melt adhesive [for example, W1500 (trade name) manufactured by Daikyo Co., Ltd.]
Can be mentioned.

The techniques described in JP-A Nos. 11-227769 and 2000-16429 are
It can be used in the present invention, and the contents described in these publications are all included in the disclosure of the present specification by reference.

Lignophenol Derivative Next, the lignophenol derivative used in the present invention will be described. As the lignophenol derivative used in the present invention, for example, (1) an acid is added to a lignocellulosic material to which a phenol derivative is added and mixed to separate the lignocellulosic material into a lignophenol derivative and a carbohydrate. At least one lignophenol derivative selected from the resulting lignophenol derivative, (2) an alkali-treated derivative of the lignophenol derivative, or (3) a hydroxyl group-protected derivative of the lignophenol derivative or the alkali-treated derivative. .

As the phenol derivative used to be added to the lignocellulosic material, a monovalent phenol derivative, a divalent phenol derivative, a trivalent phenol derivative or the like can be used. Specific examples of the monovalent phenol derivative include phenol that may have one or more substituents, naphthol that may have one or more substituents, and may have one or more substituents. Good anthrol, anthroquinoneol which may have one or more substituents and the like can be mentioned. Specific examples of the divalent phenol derivative include catechol which may have one or more substituents, resorcinol which may have one or more substituents, and one which may have one or more substituents. Examples include good hydroquinone. Specific examples of the trivalent phenol derivative include pyrogallol which may have one or more substituents.

The kind of the substituent that the phenol derivative may have is not particularly limited, and may have any substituent, but preferably, it is other than the electron-withdrawing group (halogen atom etc.). Examples of the group include an alkyl group (methyl group, ethyl group, propyl group, etc.), an alkoxy group (methoxy group, ethoxy group, propoxy group, etc.), an aryl group (phenyl group, etc.), and the like. Further, at least one of the two ortho positions of the phenolic hydroxyl group on the phenol derivative is preferably unsubstituted.
Particularly preferred examples of phenol derivatives are phenol, cresol, especially m-cresol or p-cresol.

The "lignocellulosic material" used in the present invention includes woody materials, various materials mainly made of wood, such as wood powder, chips, waste materials, and mill ends. Further, as the wood to be used, any kind of wood such as conifers and hardwoods can be used. further,
Various herbaceous plants and their related samples, such as agricultural waste, can also be used.

The acid added to the lignocellulosic material is preferably an acid having a swelling property for cellulose. Specific examples of the acid include sulfuric acid having a concentration of 65% by weight or more (for example, 72% by weight sulfuric acid), 85% by weight or more phosphoric acid, 38% by weight or more hydrochloric acid, p-toluenesulfonic acid, trifluoroacetic acid, Examples thereof include trichloroacetic acid and formic acid.

Next, the method for producing the lignophenol derivative used in the present invention will be described in more detail. The "lignophenol derivative" in the present invention means a polymer containing a diphenylpropane unit in which a phenol derivative is introduced by a C-C bond at the side chain α-position of the phenylpropane unit of lignin. . The amount and molecular weight of the introduced phenol derivative in this polymer vary depending on the lignocellulosic material as the raw material and the reaction conditions.

In order to obtain a lignophenol derivative from a lignocellulosic material, it is necessary to treat the lignin in the lignocellulosic material with the phenol derivative and extract the lignophenol derivative as a lignophenol derivative from the lignocellulosic material. Currently, there are two types of methods for extracting lignin in a lignocellulosic material as a lignophenol derivative.

The first method is the method described in JP-A-2-233701. This method is, for example, permeating a liquid phenol derivative (such as those described above, for example, phenol, cresol, etc.) into a lignocellulosic material such as wood flour, solvating lignin with the phenol derivative, and then Lignocellulosic material with concentrated acid (as described above, eg 72% sulfuric acid)
Is added and mixed to dissolve the cellulose component. According to this method, a phenol derivative in which lignin is solvated and a concentrated acid in which a cellulose component is dissolved form a two-phase separation system. Lignin solvated by a phenol derivative is contacted with an acid only at the interface where the phenol derivative phase contacts the concentrated acid phase, and the side chain α-position which is a high reaction site of the lignin basic structural unit generated by contact with the acid. The (benzylic) cation is attacked by the phenol derivative. As a result, a phenol derivative is introduced at the α-position by a C—C bond, and the benzyl aryl ether bond is cleaved to lower the molecular weight. As a result, the molecular weight of lignin is reduced, and at the same time, a lignophenol derivative in which a phenol derivative is introduced at the benzyl position of its basic constitutional unit is produced in the phenol derivative phase. A lignophenol derivative is extracted from this phenol derivative phase.
The lignophenol derivative is obtained as a part of an aggregate of a low molecular weight lignin compound obtained by cleaving a benzyl aryl ether bond in lignin. It is known that the phenol derivative may be introduced into the benzyl position via the phenolic hydroxyl group.

The lignophenol derivative can be extracted from the phenol derivative phase, for example, by the following method. That is, the phenol derivative phase is added to a large excess of ethyl ether, and the obtained precipitates are collected and dissolved in acetone. The acetone insoluble portion is removed by centrifugation, and the acetone soluble portion is concentrated. This acetone-soluble portion is added dropwise to a large excess of ethyl ether to collect the precipitate section. After distilling off the solvent from this precipitation section, it is dried in a desiccator containing phosphorus pentoxide to obtain a lignophenol derivative as a dried product. The crude lignophenol derivative can be obtained by simply removing the phenol derivative phase by vacuum distillation. In addition, the acetone-soluble part is used as it is as a lignophenol derivative solution and subjected to derivatization treatment (alkali treatment).
Can also be used for.

In the second method, a solvent (for example, ethanol or acetone) in which a solid or liquid phenol derivative is dissolved is permeated into the lignocellulosic material, and then the solvent is distilled off (collection of the phenol derivative). Dressing process). Next, concentrated acid is added to this lignocellulosic material to dissolve the cellulose component. As a result, as in the first method, the lignin solvated with the phenol derivative showed that the cation at the high reaction site (side chain α-position) of lignin generated by contact with concentrated acid was attacked by the phenol derivative, The derivative is introduced. In addition, the benzyl aryl ether bond is cleaved to lower the molecular weight of lignin. The properties of the lignophenol derivative obtained are similar to those obtained by the first method. Then, in the same manner as in the first method, the lignophenol derivative derivatized with phenol is extracted with a liquid phenol derivative. Extraction of the lignophenol derivative from the liquid phenol derivative phase can also be performed in the same manner as in the first method. Alternatively, the whole reaction solution after the concentrated acid treatment is poured into excess water, insoluble fractions are collected by centrifugation, deoxidized and dried. Acetone or alcohol is added to this dried product to extract the lignophenol derivative. In addition, this soluble section is
In the same manner as in the above method, add dropwise to excess ethyl ether,
The lignophenol derivative is obtained as an insoluble fraction. Also in this method, similarly, the acetone-soluble portion is treated as a lignophenol derivative solution and subjected to derivatization treatment (alkali treatment).
Can also be used for.

Of these two types of methods, the second method, in particular, the latter method, ie, the method of extracting and separating the lignophenol derivative with acetone or alcohol, requires a small amount of the phenol derivative. , Economical. In addition, this method is suitable for large-scale synthesis of lignophenol derivatives, since many lignocellulosic materials can be treated with a small amount of phenol derivatives. The lignophenol derivative obtained by the above method is also referred to herein as the original lignophenol derivative. In the present specification, when the term “lignophenol derivative” is used, unless otherwise specified, in addition to the original lignophenol derivative described above, those derivatives (specifically, those described below in the present specification) Specifically, all of the alkali-treated derivative or the derivative in which the hydroxyl group is protected are included.

The original lignophenol derivative obtained by the above method generally has the following characteristics. However, the features of the lignophenol derivative used in the present invention are not limited to the following. (1) The weight average molecular weight is about 3,000 to 20,000. (2) It has almost no conjugated system in the molecule, and its color tone is extremely pale. (3) It has a melting point of about 170 ° C. derived from a softwood and about 130 ° C. derived from a hardwood. (4) As a result of the selective grafting of the phenol derivative to the α-position of the side chain, the lignin derivative has a very large amount of phenolic hydroxyl groups and high phenol properties. (5) The aromatic nucleus of the lignin structural unit and the aromatic nucleus of the phenol derivative grafted at the α-position of the side chain form a diphenylmethane type structure, and self-condensation is suppressed. (6) Methanol, ethanol, acetone, dioxane, pyridine, THF (tetrahydrofuran), DMF
Easily soluble in various solvents such as (dimethylformamide).

The original lignophenol derivative obtained by the above method can be used as it is, or can be used after being further derivatized. Examples of the treatment for obtaining such a derivative include treating the original lignophenol derivative with an alkali.

The original lignophenol derivative obtained by the phase separation process from natural lignin has its active Cα blocked with the phenol derivative,
It is stable as a whole. However, under alkaline conditions, the phenolic hydroxyl groups are easily dissociated and the resulting phenoxide ion attacks adjacent Cβ-positions when sterically possible. As a result, the aryl ether bond at the Cβ position is cleaved, the lignophenol derivative is reduced in molecular weight, and the phenolic hydroxyl group in the introduced phenol nucleus is transferred to the lignin matrix. Therefore, the alkali-treated derivative is expected to be more hydrophobic than the original derivative. Further, at this time, the alkoxide ion existing at the Cγ position or the carbanion of the lignin aromatic nucleus is C
It is also expected to attack the β position, but this requires much higher energy than the phenoxide ion.
Therefore, under mild alkaline conditions, the adjacent group effect of the phenolic hydroxyl group of the introduced phenol nucleus is preferentially expressed,
Under more severe conditions, a further reaction occurs, and the phenolic hydroxyl group of the once etherified cresol nucleus is regenerated, which further lowers the molecular weight of the lignophenol derivative and increases the hydroxyl group to increase the hydrophilicity. Be expected.

Furthermore, the original lignophenol derivative and the lignophenol derivative obtained by alkali-treating the same show various properties because of the presence of phenolic and alcoholic hydroxyl groups. By protecting this hydroxyl group, a derivative having different characteristics can be obtained. Examples of the method for protecting the hydroxyl group include an acyl group (eg, an acetyl group, a propionyl group, a benzyl group, etc., preferably an acyl group).
Protecting the hydroxyl group with a protecting group such as In the present invention, the derivative in which the hydroxyl group is protected as described above can be used.

The method for producing the lignophenol derivative which can be used in the present invention is described in JP-A-2-23370.
No. 1, JP-A-9-278904, or PC
It is described in, for example, T / JP97 / 03240. The contents of all of these publications are incorporated herein by reference as part of the disclosure of the present specification. In the present invention,
The amount of the lignophenol derivative impregnated is preferably in the range of 5 to 20% with respect to the weight of the molded compressed structure fiber panel.

Manufacturing Method of Molded and Compressed Structure Fiber Panel of the Present Invention
Method The molded compressed structural fiber panel of the present invention has a substantially continuous compressed outer structural fiber portion and a thickness parallel to the plane of the lattice,
A fiber lattice including a plurality of open cells constituted by a plurality of ribs having a height that defines the thickness of the lattice and extending to a part of the surface area of each cell of the lattice opposite to the compressed skin fiber portion. A molded compressed structural fiber panel having an open cell lattice, wherein the compressed skin fiber portion, the fiber lattice portion, and the fiber flange portion are integrally molded, including a fiber flange portion that is treated with a lignophenol derivative. It can be manufactured.

The treatment with the lignophenol derivative can be carried out by any method, for example, by impregnating the molded compressed structure fiber panel with a solution containing the lignophenol derivative. For example, place a molded and compressed structure fiber panel in a container in a desiccator (pressure container), add a solution of a lignophenol derivative in an appropriate solvent (for example, acetone) to the container, and form the molded and compression structure fiber panel in the ligno. Fill with a solution of the phenol derivative. After permeating in the depressurized container for a certain period of time, taking out the molded compressed structure fiber panel from the pressure container while ventilating well with a draft and evaporating the solvent, the lignophenol derivative is attached to the molded compressed structure fiber panel. Can be made. The molded compressed structure fiber panel of the present invention treated with the lignophenol derivative obtained by the above method can exhibit excellent bending strength and water resistance. The present invention will be described in more detail with reference to the following examples, but the present invention is not limited to the examples.

[0055]

Examples Example 1: Fabrication of molded compressed skin structure fiber panel Patent No. 3048529 (Japanese Patent Application No. 8-245574)
According to the method described in (1), a molded compressed skin structure fiber panel (mat) was prepared. Made from 100% cardboard waste paper
First, water was poured into the disintegrator and cardboard waste paper was put therein, and disintegrated at 4% concentration for 30 minutes. The well disintegrated fiber raw material is diluted to 1%, poured into a mold of an elastomer pad mounted on a porous carrier, and the back surface of the porous carrier is subjected to a vacuum pressure of -700 mmHg for 1
It was dehydrated for 20 seconds. The moisture content of the mat produced at this time is 80%. The mat formed in this mold was subjected to pressure dehydration for 60 seconds under a pressure dehydrator of 11 kgf / cm ² . The moisture content of the mat at this point is about 60%. The mat formed in this mold is put into a pressure drying molding machine (high frequency press), and the upper pressure plate 195 ° C., the lower pressure plate 180 ° C., high frequency amount 50 kw / m ² , pressure 11 kg.
It was pressure dried at f / cm ^{2 for} 180 seconds. After the completion of this series of steps, the fully dried mat was removed from the mold to obtain a test mat.

Example 2 Production of Lignophenol Derivatives (1) Phenol Sorption Dry powder 2 kg 20 mesh pass wood flour (beech)
Was placed in a 25 L stainless steel tank. Lignin C ₉
An acetone solution (about 8 L) containing 3 mol of phenol per unit was quickly added, and the mixture was stirred until air bubbles disappeared. Furthermore, a stainless steel scoop was used to push the wood powder to blend well, and the lid was left for 2 days. 2 days later, open the lid,
Excessive acetone was distilled off in a fume hood, then transferred to a stainless steel long vat, and in order to avoid uneven sorption, it was thoroughly stirred with a stainless steel scoop until the wood powder was dried, and distilled off until the odor of acetone disappeared.

(2) The concentrated acid-treated sorbed wood flour was aliquoted into 3 L beakers (8 g was divided into 8 equal parts at 250 g). 72% sulfuric acid (about 0.8 L) was added in 5 or 6 times with good stirring using a glass rod each time. Initially, the wood flour was vigorously stirred so that there was no part where the wood flour was not in contact with sulfuric acid. About 10 minutes after adding the sulfuric acid, a stirrer was used (a vinyl sheet was put on to prevent scattering of the sulfuric acid). One hour after the addition of sulfuric acid, the stirring was stopped, and the reaction was stopped by pouring the mixture into a 20 L poly-container containing half of purified water. Then add purified water until the 8th minute of the container, stop stirring,
It was left for 2 days.

(3) Two days after the deoxidation treatment, the supernatant was decanted as much as possible so that the precipitate in the container was not sucked in, purified water was again added until the 8th minute, and the mixture was stirred for 15 minutes. This was repeated daily to remove acid and excess phenol. This operation was repeated 6 times until the supernatant had a pH of 6-7. (4) After the supernatant of the acid-treated precipitate in the drying container became neutral, the supernatant was decanted. Spread the precipitate on a stainless steel vat and
It was dried by a dryer set to 0 ° C. until excess water was evaporated, and further dried overnight at 60 ° C. At this time, it was taken out of the dryer every day and stirred while finely pulverizing the particles so that it was easy to dry. Then, it was dried under reduced pressure on P ₂ O ₅ until complete drying was confirmed.

(5) Acetone extraction The dry solid obtained in (4) was placed in two 5 L Erlenmeyer flasks, 4 L of acetone was added, and the mixture was stirred with occasional stirring to 3
It was left for one day to extract lignophenol. The extraction mixture was centrifuged and the supernatant was filtered using glass fiber filter paper (Whatman GF /
It was filtered in A). Acetone was added again to the extraction residue, and extraction and filtration were performed by the same procedure. (6) Distilling off acetone Acetone extract was added dropwise to diethyl ether for purification. The acetone extract prepared so as to be 20 times the weight of the lignin was placed in a separating funnel and added dropwise to 20 times the diethyl ether volume of the acetone extract which was vigorously stirred. After that, the mixture was allowed to stand for 30 minutes, the supernatant was decanted, and the precipitate section was collected by centrifugation. After drying in a fume hood for 2 days, it was dried under reduced pressure on P ₂ O ₅ to obtain powdery lignophenol.

Example 3 Treatment of Molded Compressed Skin Structure Fiber Panel with Lignophenol Derivative First, a stainless cylindrical container was placed in a desiccator (pressure container), and the mat test body 5 prepared in Example 1 was placed therein.
cm x 36 cm x 9 mm thickness, and 13 cm x 36 c
Several m × 9 mm thick pieces were put therein, and after sealing, the pressure was reduced to −760 mmHg to make the inside of the container a vacuum state.

Next, the powder lignophenol prepared in Example 2 was dissolved in an acetone solution to prepare a 10% concentration solution. This solution was gradually injected into a cylindrical container containing a mat using a tube tube. The test body was poured until it was filled with the lignophenol solution and allowed to soak in the vacuum vessel for 1 hour. Thereafter, the mat test body was taken out of the pressure vessel while well ventilating with a draft, and the acetone was sufficiently evaporated in the open air to attach the lignophenol to the mat. After drying, the weight was measured. The amount of lignophenol impregnated was calculated by subtracting the initial weight of the mat from the weight after lignophenol impregnation. The amount attached to the mat is 1 on average
It was 2%.

Example 4 Measurement of Bending Strength and Water Absorption Test Using the lignophenol-impregnated mat prepared in Example 3 and the untreated mat, a bending strength measurement and a water absorption test were conducted.

(Measurement of Bending Strength) In the measurement of the bending strength, the sub-panel shown in FIG. 1 and the full panel shown in FIG. 1 (with the ribs of the sub-panel bonded together) (each treated with a lignophenol derivative) The test was carried out by using the one that was treated and the one that was not treated. Considering that the strength of the mat after lignophenol impregnation is extremely high, the adhesive used in the production of full panels is a Kratac adhesive with high compression shear adhesive strength [Konishi Co., Ltd .: α-olefin (Klatac ) Adhesives, Product No., SH20
L] was used.

The bending strength test is conducted according to "JIS A 5908".
-1994 Particle board ". Shimadzu Autograph DCS-5000 was used as the test equipment. Specifically, it is as follows. A load with an average deformation rate of about 10 mm / min is applied from the surface of the test piece, the maximum load (P) is measured, and it is determined by the following formula. Bending strength (N / mm ² ) (kgf / cm ² ) = 3PL / 2
bt ² where P: Maximum load (N) [kgf] L: Span (mm) [cm] b: Specimen width (mm) [cm] t: Specimen thickness (mm) [cm] Bending The measurement results of the strength test are shown in Table 1 below. Numerical values in the table indicate bending strength (N / mm ² ).

[0065]

[Table 1] Sample No.1 No.2 No.3 Average lignophenol untreated subpanel 2.4 1.9 2.3 2.2 Lignophenol untreated full panel 7.3 7.3 7.5 7.4 Lignophenol treated subpanel 2.9 3.0 3.0 3.0 Lignophenol treated full panel 13.7 12.7 11.8 12.7

(Water Absorption Test) A test was conducted using the mat prepared in Example 1. The sample was left for 24 hours or more at 23 ° C. and 50% relative humidity, and then subjected to the test. The water absorption (cup method) is based on the method of JIS P 8140 and the contact time is 1
It was measured in 20 seconds. Specifically, the following operation was performed.

The edge of the cylinder that the test piece touches and the surface of the base plate are dried. Weigh the test piece to the nearest 1 mg and place it on the base plate with the measurement surface facing up. Apply the smooth-finished edge of the cylinder to the measurement surface of the test piece and tighten it sufficiently with a clamp to prevent water from leaking between the test piece and the cylinder. 100 ± 5 ml water (test area 1
(When it is 00 cm ² ) or pouring water so that the water depth in the cylinder is 10 mm. The timer is activated at the same time as pouring. Use fresh water for each measurement. After the timer is activated,
Carefully discard the water in the cylinder to prevent water from adhering to areas other than the test site within the specified time. Quickly remove the test piece and place it, test side up, on a dry blotter laid on a flat, hard surface. The dried blotter paper is placed on the test piece within a predetermined time. 2 without applying pressure to the metal roller
Roll once (one round trip) to remove excess water. right away,
Fold with the wet side of the test piece inside and quickly weigh 1 m
Measure in units of g. The number of tests is 5 for the test piece table
I went there. The water absorption was calculated according to the following formula. A = (m ₂ −m ₁ ) F where A: water absorption (cup value) (g / m ² ) m ₁ : dry mass of test piece (g) m ₂ : wet mass of test piece (g) F : 10,000 / S S: Test area (cm ² ) The measurement results of the water absorption test are shown in Table 2 below.

[0068]

[Table 2] Lignophenol-untreated items Items Number of tests Average value Maximum value Minimum value Standard deviation Water absorption (Table) (g / m ² ) 5 733.5 888.2 561.4 144 Lignophenol- treated items Items Number of tests Average value Maximum value Minimum value Standard Deviation water absorption (table) (g / m ² ) 5 17.0 18.7 12.8 2.42

(Summary of Test Results) (1) Regarding flexural strength, the difference between the untreated lignophenol and the treated was the difference between the untreated and 2.2 N / mm ² treated subpanels. Product: 3.0 N / mm ² and 3
It has increased by more than 10%, and in the full panel, it is an untreated product 7.
To 4N / mm ^2, treated product: 12.7 N / mm ² and very high strength up of more than 70% up was obtained. (2) In the water absorption test is a weak point of the paper with respect to untreated 733.5g / m ^2, as can be seen from the numerical value of treated product 17 g / m ^2, a large water repellent effect is obtained. (3) Regarding the amount of lignophenol used, the apparent density is 0.24, which is 1/4 of the apparent density of ordinary panels, due to the unique shape and structure of the mat test body. The amount worked.

[0070]

Industrial Applicability According to the present invention, it is possible to provide a molded compressed skin structure fiber panel which can be easily recycled while improving bending strength and water resistance.

[Brief description of drawings]

FIG. 1 shows the structure of a molded compression skin fiber panel for use in the present invention.

   ─────────────────────────────────────────────────── ─── Continued front page    F term (reference) 2B230 AA08 AA30 BA03 BA18 CB04                       CB06                 2B250 AA01 BA04 BA06 CA11 FA47                 2E162 CC00                 4F100 AJ04 AJ04A BA01 BA02                       BA03 DC01 DC11A DC15A                       DD22 DG01A DG10 EJ822                       GB08 JL02 JL16

Claims (5)

[Claims] 1. A fiber portion having a substantially continuous compressed skin structure and a plurality of ribs having a thickness parallel to a plane of the lattice and having a height defining the thickness of the lattice. A fiber lattice including a plurality of open cells and a fiber flange portion extending to a part of the surface area of each cell of the lattice on the opposite side of the compressed outer fiber portion, the compressed outer fiber portion and the fiber lattice portion. A molded compressed structural fiber panel obtained by treating a molded compressed structural fiber panel having an open cell lattice, which is integrally molded with the fiber flange portion, with a lignophenol derivative. 2. A lignophenol derivative is obtained by (1) adding an acid to a lignocellulosic material to which a phenol derivative has been added and mixing it to separate the lignocellulosic material into a lignophenol derivative and a carbohydrate. At least one lignophenol derivative selected from a lignophenol derivative, (2) an alkali-treated derivative of the lignophenol derivative, or (3) a hydroxyl group-protected derivative of the lignophenol derivative or an alkali-treated derivative, 1. The molded and compressed structural fiber panel according to 1. 3. The molded compressed structural fiber panel according to claim 1, wherein the amount of the lignophenol derivative impregnated is in the range of 1 to 30% based on the weight of the molded compressed structural fiber panel. 4. A lignophenol derivative produced by adding a phenol optionally having one or more substituents to a lignocellulosic material is used.
The molded and compressed structure fiber panel according to any one of items 1 to 3. 5. A fiber portion having a substantially continuous compressed skin structure and a plurality of ribs having a thickness parallel to a plane of the lattice and having a height defining the thickness of the lattice. A fiber lattice including a plurality of open cells and a fiber flange portion extending to a part of the surface area of each cell of the lattice on the opposite side of the compressed outer fiber portion, the compressed outer fiber portion and the fiber lattice portion. The molded compressed structure fiber panel according to any one of claims 1 to 4, comprising a step of treating a molded compressed structure fiber panel having an open cell lattice, which is integrally molded with the fiber flange portion, with a lignophenol derivative. Manufacturing method.