JPH02269004A - Dry manufacture of molded board - Google Patents

Abstract

PURPOSE:To constitute the title method so that a high-strength molded board is obtained, by molding an inorganic fiber after aqueous dispersions of the thermosetting resin are stuck to the inorganic fiber and dried. CONSTITUTION:An inorganic fiber is molded after aqueous dispersions of thermosetting resin are stuck to the same and dried. In other words, the aqueous dispersions of thermosetting resin are stuck to the fiber as, for example, a binder and then the fiber to which the aqueous dispersions of the resin are stuck is dried by a drier so that the fiber attains the fixed percentage of water content. An obtained material is accumulated, preheat treatment of the material is performed through heating, a product which has turned into a mat is obtained and hot-press molding of the same is performed while degassing the same. With this construction, strength of a molded board can be improved.

Description

[Detailed Description of the Invention] Industrial Application Fields> This invention is F! A relates to a method for producing cords using a dry method, and particularly relates to a method for producing cords with excellent strength and round bottoms.

Conventional technology> Conventionally, molded boards are made by adding and mixing powdered resin or resol resin to fibers.

The material is deposited, pre-heated and buried by hot roll pressing or hot air aeration, and then matted as a product.

Manufactured using hot pressure molding.

The powdered resin mentioned above is characterized by a low risk of fire outbreak, but it does not adhere to the fibers incompletely and generates dust, and in the case of M-lac resin, it produces a bad odor due to the decomposition of hexamine. There was a drawback that the work environment deteriorated, such as the occurrence of.

In order to solve the above drawbacks, water-soluble resol resins are used.

<Problems to be solved by the invention> However, water-soluble resol resins have a low molecular weight (MFI=S
If the resin has a high molecular weight (Mn±50t) or more, the gelation time is short and the fibers are not uniformly dispersed. In either case, the curing process progresses slowly (at the time of B-stage formation), density unevenness occurs, etc., and molding and deformation with good strength cannot be obtained.

Means for Solving the Problems> In view of the above circumstances, the present inventors conducted intensive studies and found that moldings produced using an aqueous dispersion of a thermosetting resin -
It was discovered that molding produced using conventional powdered or water-soluble phenolic resin has higher strength than that of 1-do. The present invention provides a method for dry manufacturing a molded board.

The method for manufacturing the molded gate in the present invention may be any known and commonly used manufacturing method, and is not limited to 1%.

For example, (1) an aqueous dispersion of a thermosetting resin as a binder
(2) Next, the fibers to which the aqueous dispersion of the resin has been adhered (hereinafter referred to as resin-containing fibers) are evenly dried in a drier or the like to a constant moisture content. (3)
The material obtained in this way is deposited, and the material is preheated (B-staged) to obtain a pine (pine) product.
4) This matted product may be subjected to black clay molding while appropriately degassing.

The organic fibers according to the present invention are fibers made of organic compounds, such as wood fibers, natural fibers such as cotton, hemp, silk, and wool, nylon, and polyester.

Examples include synthetic fibers such as polyurethane, rayon, and triacetate. Among these, wood fibers such as cellulose and lignin are preferred, and these organic fibers may be used alone or in combination of two or more types.

The aqueous dispersion of a thermosetting resin of the present invention is a known and commonly used aqueous dispersion of a thermosetting resin. Examples include aqueous dispersions prepared by dispersing in an aqueous medium.

The aqueous dispersion of thermosetting resin has a resin component of 0, 1 to 2
Since it has a fine particle shape TW of 0 μm, when it is sprayed and mixed into wood fibers, penetration into the material is suppressed and it has excellent adhesive performance. When a cellulose-based protective colloid is used to disperse the resin in an aqueous medium, its adhesive property ensures complete adhesion between the resin and the fibrous material even in a hydrated state, and the hydrated state decreases. This is preferred because the tackiness decreases and the uniform dispersibility with the fiber material becomes particularly excellent.

Examples of thermosetting resins include area resins, melamine resins, phenol resins, and co-condensed resins and modified resins thereof. Among these, resol-type phenolic resins are preferred, as they have good fluidity during hot-pressure molding; gelation time at 150°C is 30 to 30°C, since the resulting moldings have high strength and are less prone to blistering. Particularly preferred is a 180 second resol type phenolic resin.

What is the amount of the aqueous dispersion of the resin attached to the organic fibers?

It is determined by the type of organic fiber used and the target strength of the molding gate, and there is no limit to 1%, but molding should be 5 to 201% by weight (41!f fat solid content) based on the weight of the fiber (dry weight equivalent). This is preferable because the drying time during the production of the gate is short and the resulting gate has high strength. Examples of methods for adhering the aqueous dispersion of the resin to the fibers include pouring it directly onto the defibrated fibers and mixing them, and mixing the aqueous dispersion of the resin while sprinkling it on the fibers that are being mixed and stirred. Any method may be used without limitation.

In order to improve the fluidity of the resin-containing SCM and the releasability of molded beads during hot-pressure molding, waxes may be used in combination with the aqueous dispersion of the resin. The waxes are not particularly limited, and any known and commonly used waxes can be used.For example, a? silaffin wax.

Examples include silicone wax, fatty acid amides, and their rust conductors, and the preferred form is an emulsified aqueous solution. Among these, an emulsified aqueous solution of weighing fins is particularly preferred, and the amount of wax added is usually 0.1 to 1 resin (solid content).
-10111% improves the fluidity of reeds and resin-containing fibers,
The rating is preferably 1-8 in that the obtained molded board has excellent mold releasability! The amount is %.

In order to improve water resistance and durable strength, a silane coupling agent may be mixed with the aqueous dispersion of the resin. Silane coupling agents are not particularly limited, and include vinyl, amine, and epoxy.

Examples include chloro thread, methacryloxy thread, and mercapto group. Among these, amine-based silane coupling agents are particularly preferred. The amount of silica/coupling agent added is based on the resin (solid content).
What molding can be obtained with 0.1-5Xji%? −
The content is preferably 0.2 to 3% by weight since it is excellent in improving the water resistance and durable strength of the resin.

Furthermore, a conventional powdered phenol resin may be used in combination with the aqueous dispersion of the thermosetting resin, if necessary.

Furthermore, the aqueous dispersion of thermosetting resin contains the above-mentioned waxes,
In addition to silane coupling agent and powdered phenolic resin, 1
Various additives such as colorants, retardants, antioxidants, insect repellents, preservatives, water and oil repellents, antifouling agents, and fragrances may be used in combination as necessary.

When using various additives such as the above-mentioned waxes and silane coupling agents, they may be mixed in advance with the aqueous dispersion of the resin and then allowed to adhere to the aqueous resin dispersion and the additives. may be simultaneously attached to the fibers separately, or any method can be adopted, such as attaching the aqueous resin dispersion to the fibers and then attaching the additive.

The resin-containing fibers in (2) above may be dried using either an ordinary dryer or a drying mixer. Drying is preferably carried out under conditions such that the moisture content of the resin-containing fibers is 8 to 20%.

In (3) above, any conventional equipment can be used for depositing the material. Examples of such devices include fleece molding machines and air filter molding machines.

The preheating treatment is not limited in any way as long as heat is applied to the material, and examples thereof include a method of irradiating infrared rays and a method of blowing hot air.

Among these, the method of blowing hot air at 130 to 150°C is simple and preferred. A matte product is produced in this process, and this matte product usually has a thickness of 15 to 30 mm and an apparent ratio of 0.
．． 05~0.21! /am I have a question.

In the manufacturing method of the present invention, a molded board may be manufactured by first manufacturing a matted product and then performing hot-pressing molding (that is, a method that goes through the process (3) above), or the material can be directly hot-pressing molded. The molding may be used to manufacture a single head.

Conditions during hot-press molding are not particularly limited, but are usually 180 to 230°C and a pressure of 30 to 40°C.

The pressurization time is 30 to 90 seconds. It goes without saying that degassing should be carried out as appropriate during hot-pressure molding. The final molded board thus obtained is usually 2-3 + cursive.

The specific gravity is 0.70 to 1.0 cm.

The bottom mold M-do obtained by the manufacturing method of the present invention can be used, for example, as an interior material for automobiles, an interior material for houses, and a door panel material.

It can be used for furniture panel materials, ceiling materials, etc.

Next, examples of the present invention will be shown. The following, unless otherwise specified,
``Part'' means ``Jll Gunbu'' and ``%'' means ``1 foot%.''

Example 1 Breiofen pE-zol (aqueous dispersion of resol type phenolic resin manufactured by Dainippon Ink and Chemicals Co., Ltd., solid content 47%) was diluted with water in advance and adjusted to a solid content of 30%.
, average particle size 2 μm, 15 parts C gelation time 90 seconds)2
7 parts wood fiber (dry equivalent) using spray equipment 1
Spray it on 00 parts and let it adhere. Then put this into a drying mixer.

The moisture content was adjusted to 12%. Next, this material is deposited through a fleece molding machine and an air filter molding machine, and then preheated by passing heat at 130°C from the top to 1. The thickness is about 3 on, and the apparent specific gravity is about o. 1s tz/
I got a matte product from an. after that.

Temperature: 210°C, pressure: 30 kg/an, time: 60 seconds,
Degassing 1: Perform once after 15 seconds and heat-press mold to a thickness of 2.
．． A molded board with 5 lines and a specific gravity of 0.8017 cm was obtained.

Both the working environment and the mixing and dispersibility of the wood fibers and the resin were extremely good. Once molded, the mold releasability was good and rare.

Example 2 Two parts of an emulsified aqueous solution (solid content: 30%) of 11 & Shiku Glyophen PE-20127flfiK paraffin was diluted with water in advance and mixed with a solid content of 30%.

Spray this using a spray device to make wood fibers (dry equivalent) 1
00 parts by spraying and adhesion. after that.

This was placed in a drying mixer and the moisture content was adjusted to 12%.6 Next, this material was deposited through a fleece molding machine and an air filter molding machine, and the upper part was heated to 9130℃.
A matte product having a thickness of about 30 cm and an apparent specific gravity of 0.151 part cm' was obtained by preheating the product by blowing hot air through it. After that, the temperature was 210°C, the pressure was 30 kg/an, and the time was 60.
After degassing once for 15 seconds, hot-press molding is performed to a thickness of 2.
．． 5 m, molded board with specific gravity 0680 g/α: 4th order.

Both the working environment and the mixing and dispersibility of the wood fibers and the resin were extremely good. The releasability of the molded board was also extremely good.

Example 3 Dilute with water in advance to make vI4! 30% solids! ! 11
0.04 part of an amino-based silane coupling agent was mixed with 127 parts of Bryophen PE-20 which had been deformed, and the mixture was sprayed onto 100 parts of wood fibers (dry equivalent) using a spray device to make them adhere. Thereafter, this was placed in a drying mixer and the moisture content was adjusted to 12%. Next, this material is deposited through a fleece molding machine and an air filter molding machine, and then preheated by blowing hot air at 130°C through the top, giving a float of about 30 ta and an apparent ratio of about 1 to 0. 1517ar
I got a matte version of t3. After that, the pressure was 30kfl/att2° at 0°C, the pressure was 30kfl/att2°, the time was 60 seconds, and the gas was removed once after 215 seconds.
A molding of 801 parts cm was obtained.

Both the working environment and the mixing and dispersibility of the wood fibers and the resin were extremely good. The releasability of molding was good and satisfactory.

Example 4 2 parts of an emulsified aqueous solution of Dirafin (solid content 30%) and 0.04 parts of an amine-based silane cagging agent were mixed with 127 parts of Gleiophe 7 PE-20, which had been diluted with water in advance and adjusted to a solid content of 30%. This was sprayed onto 100 parts of wood fiber (dry equivalent) using a spray device to make it adhere.

Thereafter, this was placed in a drying mixer and the moisture content was adjusted to 12%. Next, after depositing this material through a fleece molding machine and an air filter molding machine,
Preheated by blowing hot air at 30°C to a thickness of approximately 30n.
A matted product with an apparent specific gravity of 151 parts m was obtained. After that, temperature 210℃, pressure 30kJan 2゜hours 6
After 0 seconds and degassing once after 15 seconds, it was hot-press molded to a thickness of 2.5 m and a specific gravity of 0.80! ! /cm (D molded board was obtained.

Both the working environment and the mixing and dispersibility of the wood fiber and the resin were extremely good. The releasability of the molded board was also extremely good.

Example 5 Water dispersion of resol resin & (solid content 47%, average particle size 2
μm, gelling time at 150°C for 50 seconds) was diluted with water to give a solid content of 30% v4, and then 27 parts of this was sprayed onto 100 parts of wood fibers (dry equivalent) using a spray device and allowed to adhere. Ta. After that, this material was placed in a drying mixer, and the moisture content was adjusted to 12%.Then, this material was deposited through a 71)-space molding machine and an air filter molding machine, and after death, the upper part was Pre-heated by blowing hot air at ℃.

A matted product with a thickness of about 30 mm and an apparent specific gravity of 0.151/arts was obtained. After that, the temperature was 210℃ and the pressure was 3゜kt.
r/an2. Time: 60 seconds, degassing once after 15 seconds, hot-press molding, thickness: 2.5 m, specific gravity: 0.809/
A molded board of art' was obtained.

Both the working environment and the mixing and dispersibility of the wood fibers and the resin were extremely good. The mold releasability after molding is good.

Example 6 An aqueous dispersion of Resol 411M ¥1 (solid content 47%, average particle diameter 2.5 μm, gelling time at 150°C 170 seconds) was diluted with water to a solid content of 30%, and then this 27 Department,
Using a spray device, 100 parts of wood fibers (dry equivalent) were sprayed and adhered. Thereafter, this was placed in a drying mixer and the moisture content was adjusted to 12%. Next, this material is deposited through a fleece molding machine and an air filter molding machine, and then preheated by blowing hot air at a temperature of 130°C through the upper part.
A matted product of /A-IL' was obtained. Then temperature 210
°C, pressure 30 kg/x, time 60 seconds, degassing 1
After 5 seconds, hot pressure molding was carried out once to obtain a molded gate having a thickness of 2.5 mm and a specific gravity of 0.8011/cm.

Both the working environment and the mixing and dispersibility of the wood fibers and the resin were extremely good. The releasability of the molded gate was also good.

Comparative example 1 Commercially available water-soluble resol resin (solid content 50%).

150℃ gelation time 90 seconds) was diluted with water to reduce the solid content to 3.
After adjusting to 0%, this was sprayed onto 100 parts of wood fibers (dry equivalent) using a Sugrei machine and adhered to nine pieces. .1
A mattification of 511/cm was obtained.

After that, the temperature was 210°C and the pressure was 30 kg/an2. Heat and pressure molding was performed for 60 seconds and degassing once after 15 seconds to obtain a molded gate with a thickness of 2.5 mm and a specific gravity of 0.801/an.

The working environment was extremely good. Although the mixing and dispersibility of the wood fiber and the resin was extremely poor, the mold release property was good when the molding was 0.

Comparative Example 2 Commercially available powdered Nogelac resin (gelling time at 150°C 9
0 seconds, containing 10% hesamine. ) was sprayed and mixed onto 100 parts of wood fiber #1 (dry equivalent) to make it adhere. after that,
The process was the same as in Example 1, except that the material was deposited through a fleece molding machine and an air filter molding machine, with a thickness of about 30 fl,
A matted product with an apparent specific gravity of 0.151 parts cm was obtained. After that, the temperature was 210°C and the pressure was 30 kl/an2. time 6
After 0 seconds and degassing once after 15 seconds, it was hot-press molded to a thickness of 2.51 specific gravity.

A wood-based molded board of 0.801/an3 was obtained.

The working environment was very bad due to the dust. The resin did not adhere uniformly to the wood fibers, resulting in extremely poor mixing and dispersibility. or,
Powder falling phenomenon was also observed. Molding s? - The mold releasability of the mold was somewhat poor.

Comparative Example 3 Commercially available powdered resol resin (gelling time at 150°C 90
Sprinkle 8 parts (second) on 100 parts of wood fiber (dry equivalent), mix, and adhere. Thereafter, this material was deposited through a fleece molding machine and an air filter molding machine, and nine pieces were deposited in the same manner as in Example 1, with a thickness of approximately 30 mm and an apparent specific gravity of 0.151.
A mattification of 17/crIL' was obtained. Then temperature 21
0°C, pressure 30 ky/an2° time 60 seconds, degassing once after 15 seconds, hot pressure molding, thickness 2.5 m,
A wood molding with a ratio g O of 80 Ji'/cm was obtained.

The working environment was extremely poor with dust flying around. The resin did not adhere uniformly to the wood fibers, resulting in extremely poor mixing and dispersibility. or,
Powder falling phenomenon was also observed. The releasability of the molded board was also somewhat poor.

The appearance of the molded gates obtained in Examples and Comparative Examples is shown below.
The normal bending strength was measured and the results are shown in Table 1.

/ Notes to the table $1) The strength of normal songs conforms to JIS-A5907.

<Effects of the Invention> Since the dry manufacturing method of the molded boat 9 of the present invention uses an aqueous dispersion of thermosetting resin, the strength is significantly increased compared to conventional molded gates using powdered or water-soluble phenolic resin. The strength can be further improved by using a silane coupling agent in combination, and the mold releasability during molding of the molding mate can be improved by using a wax in combination.

Since the molded board produced by the method of the present invention has high strength, it can be used for six purposes, including automobile interior materials, residential interior materials, door panel materials, furniture/base panel materials, and ceiling materials.

Claims (1)

[Scope of Claims] 1. A dry manufacturing method for a molded board, characterized in that an aqueous dispersion of a thermosetting resin is applied to organic fibers, dried, and then molded. 2. The manufacturing method according to claim 1, wherein the fibers are wood fibers. 3. The manufacturing method according to claim 2, wherein the thermosetting resin is a resol type phenolic resin. 4. Thermosetting resin has a gelation time of 30 at 150°C.
Claim 2, which is a resol-type phenolic resin that lasts for ~180 seconds.
Manufacturing method described. 5. The manufacturing method according to claim 2, characterized in that a wax is used in combination with a thermosetting resin. 6. The method according to claim 2, characterized in that a silane coupling agent is used in combination with a thermosetting resin.