WO2006040976A1 - 繊維成形体の製造方法及び装置、繊維成形中間体並びに繊維成形体 - Google Patents
繊維成形体の製造方法及び装置、繊維成形中間体並びに繊維成形体 Download PDFInfo
- Publication number
- WO2006040976A1 WO2006040976A1 PCT/JP2005/018440 JP2005018440W WO2006040976A1 WO 2006040976 A1 WO2006040976 A1 WO 2006040976A1 JP 2005018440 W JP2005018440 W JP 2005018440W WO 2006040976 A1 WO2006040976 A1 WO 2006040976A1
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- Prior art keywords
- fiber
- molded body
- mold
- fiber molded
- producing
- Prior art date
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Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
- D21J3/00—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds
- D21J3/10—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds of hollow bodies
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
- D21J7/00—Manufacture of hollow articles from fibre suspensions or papier-mâché by deposition of fibres in or on a wire-net mould
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Definitions
- the present invention relates to a method for producing a fiber molded body, a production apparatus including a papermaking mold used therefor, a fiber molding intermediate, and a papermaking molded body.
- a method for producing a fiber molded body there is known a method for producing a fiber molded body by producing a fiber laminated body containing a fiber material, placing the fiber laminated body in a mold and performing press molding. Speak.
- a production method there is a step of obtaining a wet fiber laminate from a slurry containing a fiber material, placing the fiber laminate in a drying mold heated to a desired temperature, drying and pressing. Widely adopted.
- a molten metal (hereinafter referred to as a molten metal) is supplied to the cavity. Corners (corner portions of individual fiber molded products) When the top of 113 is rounded, a wedge-shaped gap is formed in the rounded portion (see Fig. 23), and molten metal enters the gap, This becomes a so-called burr, and it is necessary to remove the burr. If the burr is large, it becomes defective. Further, the mating surfaces may be pushed open by the molten metal that has entered the gap, resulting in defective articles.
- the apex of the corner portion (corner portion of each fiber molded body) of the mating surface is sharp.
- sharpening is synonymous with minimizing the radius of curvature of the corners.
- Patent Document 1 Japanese Patent Application Laid-Open No. 57-47999 Disclosure of the invention
- the present invention has been made in view of the above problems, and provides a method for producing a fiber molded body capable of sharpening the apex of the corner of a fiber molded body having corners, and a papermaking mold used therefor. It is an object of the present invention to provide a manufacturing apparatus, a fiber forming intermediate, and a fiber molded body.
- the present invention relates to a method for producing a fiber molded body having corners on a mating surface with another fiber molded body after making a fiber laminated body containing a fiber material and then press-molding the fiber laminated body. Therefore, the object is achieved by providing a method for manufacturing a fiber molded body in which thick portions are provided at or near the corners of the fiber laminate, and the thick portions are pressed.
- the present invention is a papermaking mold used in the method for producing a fiber molded body of the present invention, wherein the papermaking mold for forming the thick portion at the intersection of two surfaces of the fiber laminate is provided. It is provided.
- the present invention is a papermaking mold used in the method for producing a fiber molded body of the present invention, wherein a base surface portion is formed to form the thick portion in a papermaking portion where the fiber laminate is made.
- the present invention provides a papermaking mold that is provided at a position lower than the butted portion and has a recess.
- the present invention is a papermaking mold for use in the method for producing a fiber molded body of the present invention, wherein a groove for papermaking the thick portion is provided in a papermaking portion where the fiber laminate is made.
- the papermaking mold is provided.
- the present invention includes a papermaking mold for the fiber laminate and a receiving mold for receiving the fiber laminate from the papermaking mold, and a base portion of the overhang portion is bent on the papermaking mold or the receiving mold. Then, the manufacturing apparatus of the fiber molded object which comprises the thick part formation means which forms the said thick part is provided.
- the present invention is a fiber molding intermediate for use in a method for producing a fiber molded body having a corner continuous with a mating surface with another member, and is made from a slurry containing a fiber material.
- Fiber molding comprising a fiber laminate in a wet state, and a thickened portion in which the fiber laminate is partially bent is provided at or near the corner of the fiber laminate corresponding to the corner.
- An intermediate is provided.
- the present invention also relates to a fiber molded body obtained by forming a fiber laminate containing a fiber material and then press-molding the fiber laminate, and the intersection of two surfaces of the fiber molded body
- the present invention provides a fiber molded body in which the apex of the corner formed in the portion is sharp.
- the present invention also provides a fiber molded body in which a plurality of fiber molded bodies are combined to form a cavity, and the fiber molded body having sharp apexes at the corners of the mating surface.
- FIG. 1 is a partial cross-sectional view schematically showing a first embodiment of a production apparatus for carrying out the method for producing a fiber molded body of the present invention.
- FIG. 2 is a perspective view, partially broken away, schematically showing the first embodiment of the papermaking mold of the present invention.
- FIG. 3 is a perspective view schematically showing a male mold provided in the dry forming means of the manufacturing apparatus.
- FIG. 4 is a diagram schematically showing a paper making process in the first embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 5 is a diagram schematically showing a transition process of the fiber laminate after the paper making process in the first embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 6 is a cross-sectional view schematically showing a dry molding process in the first embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 7 is a cross-sectional view schematically showing a demolded state after the dry molding process in the first embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 8 is a diagram schematically showing a drying molding process in the first embodiment of the method for producing a fiber molded body of the present invention.
- Fig. 9 is a view schematically showing a demolded state after the dry molding step in the first embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 10 is a perspective view showing an embodiment of the fiber forming intermediate body of the present invention produced by the method for producing a fiber molded body of the present invention.
- FIG. 11 (a) shows the change in the shape of the thick part before and after the dry molding.
- FIG. 11 (b) is a cross-sectional view after the dry molding showing the change in the shape of the thick portion before and after the dry molding.
- FIG. 12 (a) is a diagram showing an embodiment of the fiber molded body of the present invention produced by the method for producing a fiber molded body of the present invention, and shows two fiber molded bodies. It is a figure which shows the state which has faced
- FIG. 12 (b) is a view showing an embodiment of the fiber molded body of the present invention manufactured by the method for manufacturing a fiber molded body of the present invention. It is an enlarged view of corner parts.
- FIG. 13 is a partial cross-sectional view schematically showing a second embodiment of a production apparatus for carrying out the method for producing a fiber molded body of the present invention.
- FIG. 14 is a partially cutaway perspective view schematically showing a second embodiment of the papermaking mold of the present invention.
- FIG. 15 is a diagram schematically showing a papermaking process in the second embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 16 is a diagram schematically showing the transition process of the fiber laminate after the paper making process in the second embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 17 is a diagram schematically showing a dry molding step in the second embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 18 is a diagram schematically showing a demolded state after completion of the dry molding step in the second embodiment of the method for producing a fiber molded body of the present invention.
- FIG. 19 is a perspective view showing another embodiment of the fiber forming intermediate body of the present invention produced by the method for producing a fiber molded body of the present invention.
- FIG. 20 (a) is a diagram showing a change in the shape of the thick portion before and after the dry molding, and is a cross-sectional view before the dry molding.
- FIG. 20 (b) is a diagram showing a change in the shape of the thick portion before and after the dry molding, and is a cross-sectional view after the dry molding.
- Fig. 21 (a) schematically shows changes in the shape of the thick part before and after dry forming. It is a fragmentary sectional view and is a sectional view before dry molding.
- FIG. 21 (b) is a partial cross-sectional view schematically showing a change in the shape of the thick portion before and after dry forming, and is a cross-sectional view after dry forming.
- FIG. 22 is a diagram schematically showing another embodiment of the male mold provided in the dry molding means of the production apparatus of the present invention.
- FIG. 23 is a schematic diagram for explaining a problem of formability of a fiber molded body in the prior art.
- FIG. 1 to 3 schematically show a first embodiment of a production apparatus for carrying out the method for producing a fiber molded body of the present invention.
- reference numeral 1 denotes a manufacturing apparatus.
- the production apparatus 1 is a saddle type comprising a semi-cylindrical fiber molded body 11 having a flange portion 111 which is an embodiment of the fiber molded body of the present invention (see FIG. 12).
- a raw material supply means 2 for supplying a raw material slurry, a paper making means 3 for making a wet fiber laminate (fiber forming intermediate) from the raw material slurry supplied from the raw material supply means 2, and And a dry molding means 4 for dry-molding the manufactured fiber laminate.
- the two half-cylindrical fiber molded bodies 11 are combined to form a saddle-shaped cavity.
- the raw material supply means 2 includes an injection frame 20, a vertical movement mechanism 21 that moves the injection frame 20 up and down, and a slurry supply pipe 22 that supplies the raw material slurry into the injection frame 20.
- the slurry supply pipe 22 is provided with a valve 23.
- the papermaking means 3 includes a papermaking mold 30 having a so-called male shape.
- the papermaking mold 30 has a papermaking part 300 corresponding to the shape of the fiber laminate to be papermaking.
- the papermaking section 300 is provided with a gas-liquid flow passage 301 (see FIG. 2) that opens on the surface thereof, and a discharge pipe 303 connected to the suction pump 302 is connected to the gas-liquid flow passage 301.
- a valve 304 is disposed in the discharge pipe 303.
- a papermaking net 305 is arranged on the surface of the papermaking part 300.
- the papermaking mold 30 has a flange portion 101 (a tension member) of the fiber laminate 10 of the papermaking portion 300.
- a base surface portion 306 corresponding to the upper surface portion of the protruding portion (see FIG. 10) is provided at a lower position than the abutting surface 309 to form a recess 310.
- the depth of the concave portion 310 is such that the base portion of the flange portion 101 is bent when the paper laminate 30 and the female die (receiving die) 40 described later are combined to release the fiber laminate 10, and the thick portion 104 (see Fig. 10) is set to the depth to be formed.
- the depth of the recess 310 (the depth from the butt surface 309) is suitably 1 to 20 mm, and more preferably 3 to 8 mm.
- the dry molding means 4 includes a female mold (receiving mold) 40 and a male mold 41.
- a gap (clearance) corresponding to the outer shape of the fiber molded body to be molded is formed between these molds.
- the gap is formed so that the flange portion 101 of the fiber molded body 11 is substantially flush with the female die 40 when the female die 40 and the male die 41 are brought into contact with each other.
- the female mold 40 has a concave molded portion 400 corresponding to the outer shape of the fiber molded body 11 to be obtained.
- the female die 40 is provided with a heater (heating means) 401 for heating the molding part 400.
- the female mold 40 is moved up and down by the vertical movement means 402.
- the female mold 40 is provided with a gas-liquid flow passage (not shown) that opens in the molding portion 400.
- a circulation pipe 403 that leads to a suction pump and a compressor (both not shown) is connected to the gas-liquid flow passage.
- the circulation pipe 403 is provided with a valve 404.
- the forming portion 400 has a step portion 406 that is recessed from the abutting surface 405 of the female mold 40 and into which the flange portion 111 of the fiber formed body 11 is accommodated, and this step portion 406 forms a part of a space forming portion that will be described later. Is done.
- the female mold 40 is provided with a gas-liquid flow passage 407 (see FIG. 6) that opens at the step 406 and communicates with the flow pipe 403.
- the male die 41 has a convex shaped portion 410 corresponding to the inner shape of the fiber molded body 11 to be obtained.
- the surface of the molded part 410 is coated with fluorine resin.
- the molding part 410 of the male mold 41 is provided with a gas-liquid flow passage 411 (see FIG. 3) opened on the surface thereof, and the gas-liquid flow path 411 has a discharge pipe 41 3 connected to the suction pump 412. Is connected.
- a nozzle 414 is arranged in the discharge pipe 413.
- a concave portion may be formed on the surface of the fiber forming intermediate body at a portion corresponding to the hole of the gas-liquid flow passage 411, and a concave portion may remain on the surface of the article.
- the machine tool It may be necessary to finish the surface of porcelain products.
- the gas-liquid flow passage 411 may be omitted.
- a heater or the like (heating means) for heating the molding part 410 is arranged inside the molding part 410.
- the manufacturing apparatus 1 causes the papermaking mold 30 and the female mold 40 to bend the base portion of the flange portion 101 of the fiber laminate 10 to form the thick portion 104 (see FIG. 10).
- Thick part forming means 6 to be formed is provided.
- the thick part forming means 6 includes a separating means 60 for separating the outer edge portion of the flange 101 of the fiber laminate 10 from the papermaking mold 30 when the papermaking mold 30 and the female mold 40 are combined.
- the space forming portion 61 is disposed between the mold 40 and forms a bent space of the base portion.
- the separating means 60 is constituted by the gas-liquid flow passage 407 opening in the stepped portion 406, the flow pipe 403 connected to the gas-liquid flow passage 407, and the suction pump.
- the space forming part 61 is constituted by a concave part 310 of the papermaking mold 30 and a step part 406 of the female mold 40.
- the gas-liquid flow passage 407 may be piped more densely than the other parts so that the suction force acts on the outer edge of the flange part of the fiber laminate 10 at the step part.
- the manufacturing apparatus 1 includes moving means (not shown) that moves the papermaking mold 30 and the male mold 41 to predetermined positions along the guide 50. Further, the manufacturing apparatus 1 includes control means (not shown) provided with a sequencer that is connected to each of the above-described means and operates each of the means in accordance with a procedure that will be described later.
- reference numeral 10 denotes a fiber laminate
- 11 denotes a fiber molded body.
- the method for producing a fiber molded body of the present embodiment includes making a wet fiber laminate 10 (see FIG. 10) from a raw material slurry containing a fiber material, and then removing the fiber laminate 10 from the paper mold 30 to the female.
- the fiber laminate 10 is press-molded with the female mold 40 and the male mold 41, and the fiber molded body 11 (see FIG. 12) is manufactured.
- a raw material slurry is prepared by dispersing inorganic powder, inorganic fiber, organic fiber, thermosetting resin and heat-expandable particles in a dispersion medium.
- the raw slurry is manufactured
- the one prepared so as to be compatible with the molded body is used.
- the dispersion medium include water, white water, solvents such as ethanol and methanol, and mixed systems thereof.
- the mixing ratio (mass ratio) of each component in the raw slurry is inorganic powder, inorganic fiber, organic fiber.
- Inorganic powder Z inorganic fiber Z organic fiber Z thermosetting resin and thermally expandable particles 70 to 80% Z2 to 8% Z 0 to 10% with respect to the total mass of the thermosetting resin and thermally expandable particles Z8 to 16% (mass ratio) is preferable 70 to 80% ⁇ 2 to 6% ⁇ 0 to 6% ⁇ 10 to 14% (mass ratio) is more preferable.
- the total of inorganic powder, inorganic fiber, organic fiber, thermosetting resin and thermally expandable particles is 100% by mass.
- the blending ratio of the inorganic fibers When the blending ratio of the inorganic fibers is within such a range, the moldability and shape retention at the time of filling are good. If the blending ratio of the organic fibers is within this range, the moldability is good. The amount of gas generated by combustion of organic fibers at the time of swallowing, and the amount of organic fibers to suppress blowing out of the flame from the frying may be as low as possible. When the blending ratio of the thermosetting resin and the heat-expandable particles is within such a range, the moldability of the molded body, the shape retention after swallowing, and the surface smoothness are good.
- Examples of the inorganic powder include graphite such as plate-like graphite and earth-like graphite, obsidian, and mullite. These inorganic powders can be used alone or in combination of two or more. From the viewpoint of formability and cost, it is preferable to use graphite, particularly plate-like graphite.
- the inorganic fiber mainly forms a skeleton of a molded body, and maintains its shape without being burned by the heat of molten metal during fabrication.
- the inorganic fibers include carbon fibers, artificial mineral fibers such as rock wool, ceramic fibers, and natural mineral fibers, which can be used alone or in combination of two or more.
- PAN-based carbon fiber is preferred.
- the inorganic fiber has a dehydrating property when a fiber laminate is made and dehydrated. From the viewpoint of moldability and uniformity, an average fiber length of 0.5 to 15 mm, particularly 3 to 8 mm is preferred.
- Examples of the organic fiber include paper fiber (pulp fiber), fibrillated synthetic fiber, regenerated fiber (for example, rayon fiber), and the like.
- the organic fibers can be used alone or in combination of two or more. Paper fiber is preferable from the viewpoints of moldability, strength after drying, and cost.
- Examples of the paper fiber include wood pulp, cotton pulp, linter pulp, bamboo straw and other non-wood pulp.
- these virgin pulp or waste paper pulp can be used alone or in combination of two or more.
- the paper fiber is particularly preferably used paper pulp from the viewpoints of easy availability, environmental protection, and reduction of manufacturing costs.
- the organic fiber has an average fiber length of 0.8 to 2. Omm, particularly 0.9 to 1.8 mm in consideration of moldability, surface smoothness, and impact resistance of the molded body. preferable.
- the thermosetting resin is a component necessary for maintaining the room temperature strength and hot strength of the molded body, improving the surface properties of the molded body, and improving the surface roughness of the molded article.
- the thermosetting resin include phenol resin, epoxy resin, and furan resin. Among these, in particular, there is an effect of suppressing combustion with less generation of combustible gas, and a good carbonized film can be obtained by forming a carbonized film with a high residual carbon ratio of 25% or more after pyrolysis (carbonization). It is preferable to use phenol resin for the point power that can be used.
- phenol resin a novolak phenol resin that requires a hardener and a resol type phenol resin that requires a curing agent are used.
- novolac phenol resin a curing agent is required. Since the curing agent is easily soluble in water, it is preferably applied to the surface of the molded body after dehydration. It is preferable to use hexamethylenetetramine or the like as the curing agent.
- the thermosetting resin can be used alone or in combination of two or more.
- the raw slurry contains 0.5 to 10% (mass%) of thermally expandable granules with respect to the total mass of the inorganic powder, inorganic fibers, organic fibers, thermosetting resin and thermally expandable particles. It is preferable to contain 1 to 5% (mass%).
- the shaped body of the present embodiment includes the thermally expandable particles that expand and have an average diameter of preferably 5 to 80 ⁇ m, more preferably 25 to 50 m. If the expansion of the heat-expandable particles is within such a range, the effect of addition can be sufficiently obtained while suppressing the adverse effect on the molding accuracy due to expansion.
- the heat-expandable particles are preferably microcapsules in which an expansion agent that expands by vaporization is encapsulated in the shell wall of thermoplastic resin.
- the microcapsules When heated at 80-200 ° C, the microcapsules preferably have a diameter that is 3-5 times, a volume that is preferably 50-: an average particle size that expands to LOO times, preferably 5-60 ⁇ m, and more. A particle size of 20 to 50 ⁇ m is preferable.
- thermoplastic resin constituting the shell wall of the microcapsule examples include polystyrene, polyethylene, polypropylene, polyacrylonitrile, acrylonitrile-salt-vinylidene copolymer, ethylene vinyl acetate copolymer, or a combination thereof. Can be mentioned.
- expanding agent contained in the shell wall include low-boiling organic solvents such as propane, butane, pentane, isobutane, and petroleum ether.
- the raw material slurry includes paper strength reinforcing materials such as polybutyl alcohol, carboxymethyl cellulose (CMC), polyamidoamine chlorohydrin resin, flocculants, colorants, and the like. Other components can be added at an appropriate ratio.
- paper strength reinforcing materials such as polybutyl alcohol, carboxymethyl cellulose (CMC), polyamidoamine chlorohydrin resin, flocculants, colorants, and the like.
- CMC carboxymethyl cellulose
- Other components can be added at an appropriate ratio.
- the injection frame 20 is lowered by the vertical movement mechanism 21, the valve 23 is opened, and the slurry is supplied into the injection frame 20 through the slurry supply pipe 22. Is done.
- the valve 23 is closed and the slurry supply is stopped.
- the valve 304 is opened, and the liquid content of the slurry is sucked by the suction pump 302 through the gas-liquid flow passage 301 and the discharge pipe 303, and the solid content is deposited on the surface of the papermaking net 305 and is in a wet state.
- a fiber laminate 10 is formed.
- the liquid content in the fiber laminate 10 is such that the handleability of the fiber laminate 10 and the flow of the fiber laminate 10 when the fiber laminate 10 is pressed between the female mold 40 and the male mold 41 are pressed. Considering deformation (it is better to be deformed to some extent by pressing), it is preferable that the liquid content is 50 to 200 parts by mass with respect to 100 parts by mass of the solid content in the fiber laminate 10 70: LOO mass More preferably, it is a part.
- the liquid content is adjusted by suction of the liquid component through the suction pump 302, and the suction is stopped when the predetermined liquid content is reached.
- the mass moisture content before use of the molded body is preferably 8% or less. 3% or less is more preferable.
- the female mold 40 is lowered by the vertical movement mechanism 402 and is brought into contact with the papermaking mold 30.
- the concave space 310 of the papermaking mold 30 and the stepped portion 406 of the female mold 40 form a bent space of the base portion of the flange portion 101 of the fiber laminate 10.
- the fiber laminate 10 When the fiber laminate 10 is removed from the papermaking mold 30, the fiber laminate 10 is adsorbed on the molding surface 400 side through the flow pipe 403 in the female mold 40. At this time, as shown in FIG. 6, the flange portion 101 of the fiber laminate 10 is sucked through the gas-liquid flow passage 407 that opens at the outer edge force step portion 406 of the flange portion 101 and is separated from the papermaking mold 30, and the flange portion. The base portion of 101 is bent to form the thick portion 104.
- the female mold 40 is pulled up by the vertical movement mechanism 402 as shown in FIG. 7, and then the fiber laminate 10 is delivered from the papermaking mold 30 to the female mold 40. Then, it is moved to the dry molding position with the male mold 41 by the moving means. As shown in FIGS. 10 and 11 (a), the fiber laminate 10 made and formed in this way has an intersection of the flange portion 101 and the peripheral wall portion 102 in the flange portion 101 (two points). A thick portion 104 is formed at the edge of the corner 103 formed at the intersection of the surfaces.
- the female mold 40 is lowered by the vertical movement mechanism 402. Then, the fiber laminate 10 is pressed against the male mold 41 heated to a predetermined temperature and pressed between the male and female molds, and a dried fiber molded body 11 is obtained.
- the apex of the corner 113 formed at the intersection (intersection of the two surfaces) of the flange 111 and the peripheral wall 112 in the fiber molded body 11 becomes sharp (FIG. 11 (b)).
- a gap for accommodating the thick portion 104 is not formed. That is, according to the shape of the fiber molded body to be finally formed (not having a thick portion) A void is formed. If the apex of a sharp corner touches another object
- the density of the apex of the corner 113 is preferably 0.8 gZcm 3 or more in order to prevent damage.
- the mold temperatures of the female mold 40 and the male mold 41 are appropriately set according to the fiber molded body to be manufactured. However, in consideration of prevention of scorching of the fiber laminate 10, 100 to 250 ° C is preferable. 120-200 ° C is more preferable.
- the pressure of the press molding by the female mold 40 and the male mold 41 is preferably 0.2 MPa to 10 MPa, more preferably 0.5 MPa to 5 MPa in consideration of surely crushing the thick portion. However, the pressure of press molding may vary greatly depending on the type and strength of the material constituting the fiber molded body.
- the valve 414 is open, and the moisture in the fiber laminate 10 is sucked by the suction pump 412 through the gas-liquid flow passage 411 (see FIG. 3) and the discharge pipe 413 to the outside. Discharged.
- the injection frame 20 is lowered by the vertical movement mechanism 21, and the papermaking portion 301 of the papermaking mold 30 is included in the injection frame 20 again. Then, the fiber laminate is newly made in the same manner as in the paper making step.
- the suction from the flow pipe 403 is switched to the air injection by the compressor, and the female mold 40 is pulled up by the vertical movement mechanism 402 as shown in FIG. Then, after the suction by the suction pump 412 is stopped, the fiber molded body 11 remaining on the male mold 41 side is removed from the male mold 41, and the production of the fiber molded body 11 is completed. In addition, the injection frame 20 is pulled up by the vertical movement mechanism 21, and the new fiber laminate 10 that has finished the paper making process is then transferred to the heating process. In the manufacturing method of the present embodiment, such paper making and dry forming steps are repeatedly performed.
- the thickness of the molded body of the present embodiment is set according to the application.
- the thickness of the molded body is preferably 0.2 to 5 mm, more preferably 0.7 to 1.5 mm. When the thickness is within this range, the above-mentioned strength can be sufficiently secured while suppressing the influence of the expansion of the thermally expandable particles on the moldability, and the generation of gas during fabrication can also be suppressed. .
- a convex portion or the like is provided on a part of the flange portion 101 projecting in an annular shape, so that pouring is performed.
- a gas vent at the time of filling can be appropriately provided.
- FIGS. 13 to 15 schematically show a second embodiment of a production apparatus for carrying out the method for producing a fiber molded body of the present invention.
- reference numeral 1 denotes a manufacturing apparatus. Further, parts common to the manufacturing apparatus of the first embodiment are denoted by the same reference numerals, and description thereof is omitted.
- the manufacturing apparatus 1 ′ manufactures a semi-cylindrical fiber molded body 11 ′ (see FIG. 12) having a flange portion 111 and supplies a fiber slurry as a raw material.
- Raw material supply means 2 paper making means 3 for making a wet fiber laminate (fiber forming intermediate) from the fiber slurry supplied from raw material supply means 2, and dry forming means for dry forming the paper fiber laminate come with 4 and speak.
- the papermaking portion 300 of the papermaking mold 30 'of the papermaking means 3 corresponds to the peripheral wall portion of the fiber laminate from the base surface portion 306 corresponding to the upper surface portion of the flange portion of the fiber laminate.
- a groove 308 is provided at the rising portion of the convex surface portion 307. As will be described later, the groove 308 allows the fiber laminate 10 ′ (see FIG. 19 and FIG. 20 (a)) to be manufactured to have a corner portion 103 formed at the intersection of the flange portion 101 and the peripheral wall portion 102.
- a thick portion 104 ′ is formed in the vicinity.
- the width of the groove 308 is suitably 1 mm to 10 mm so that the fibers are densely stacked, and more preferably 3 mm to 6 mm.
- the depth of the groove 308 is suitably 1 mm to 10 mm so that the shape does not deviate greatly when the fiber laminate is put on the male mold 41, especially 3 mn! ⁇ 5mm is desirable.
- the dry molding means 4 includes a female mold 40 and a male mold 41.
- a gap (clearance) corresponding to the outer shape of the fiber molded body to be molded is formed between these molds.
- the female mold 40 has a concave molded portion 400 corresponding to the outer shape of the obtained fiber molded body 11.
- the female mold 40 includes a heater (heating means) 401 for heating the molding part 400.
- the female mold 40 moves up and down by the vertical movement means 4 02.
- the female die 40 is provided with a gas-liquid flow passage (not shown) that opens in the molding portion 400.
- Distribution pipe 403 404 is provided.
- the male die 41 has a convex shaped portion 410 corresponding to the inner shape of the obtained fiber molded body 11.
- the surface of the molding part 410 is coated with fluorine resin.
- the molding part 410 of the male mold 41 is provided with a gas-liquid flow passage (not shown) opened on the surface thereof, and a discharge pipe 413 leading to the suction pump 412 is connected to the gas-liquid flow passage. ing.
- a valve 414 is disposed in the discharge pipe 413.
- a heater heating means for heating the molding unit 410 is disposed inside the molding unit 410.
- the manufacturing apparatus 1 ′ includes moving means (not shown) for moving the papermaking mold 30 ′ and the male mold 41 to predetermined positions along the guide 50. Further, the manufacturing apparatus 1 ′ includes control means (not shown) provided with a sequencer that is connected to each of the above-described means and operates each of the means according to a procedure described later.
- FIG. 12 a preferred embodiment of the method for producing a fiber molded body of the present invention is shown in Fig. 12 and Figs. 15 to 20 based on the method for producing a fiber molded body using the production apparatus 1 '.
- reference numeral 10 ' denotes a fiber laminate
- 11' denotes a fiber molded body.
- the injection frame 20 is lowered by the vertical movement mechanism 21, the valve 23 is opened, and the raw material slurry is fed into the injection frame 20 through the slurry supply pipe 22. Supplied.
- the valve 23 is closed and the supply of the slurry is stopped.
- the valve 304 is opened, and the liquid content of the slurry is sucked by the suction pump 302 through the gas-liquid flow passage 301 and the discharge pipe 303, and the solid content is deposited on the surface of the papermaking net 305, and the wet fiber laminate A body 10 'is formed.
- the liquid content in the fiber laminate 10 ′ is determined by the handling properties of the fiber molded body 10 ′ and the fiber lamination due to the flow of fibers when the fiber laminate 10 is pressed between the female mold 40 and the male mold 41. Considering the deformation of the body 10, it is better to make the liquid content 50-200 parts by mass with respect to 100 parts by mass of the solid content in the fiber molded body 10 '. 70 to 100 parts by mass is more preferable.
- the liquid content is adjusted by suction of the liquid component through the suction pump 302, and the suction is stopped when the predetermined liquid content is reached.
- the fiber laminate 10 'made in this way has an intersection (two points) between the flange 101 and the peripheral wall 102 in the flange 101.
- a thick portion 104 ′ is formed at the edge of the corner 103 formed at the intersection of the two surfaces).
- the thickness and shape of the thick part 104 ' is controlled by the papermaking groove 308.
- the width is 3mn! ⁇ 6mm, 3mn thickness! If it has a similar volume and installation location, it is desirable to set the shape freely.
- the female mold 40 is lowered by the vertical movement mechanism 402 and is brought into contact with the papermaking mold 30 '.
- the female mold 40 is pulled up by the vertical movement mechanism 402, and fiber lamination is performed from the papermaking mold 30 to the female mold 40.
- Body 10 ' is handed over.
- the female mold 40 is then moved to the dry molding position with the male mold 41.
- the female mold 40 is lowered by the vertical movement mechanism 402 and is brought into contact with the male mold 41 heated to a predetermined temperature, and fiber lamination is performed between these male and female molds.
- the body 10 ' is press-molded to obtain a dried fiber compact.
- the apex of the corner 113 formed at the intersection of the flange 111 and the peripheral wall 112 in the fiber molded body 11 becomes sharp (FIG. 20 (b)).
- a gap for accommodating the thick portion 104 ′ is not formed. That is, a gap corresponding to the shape of the finally formed fiber molded body (not having a thick portion) is formed.
- the apex of a sharp corner comes into contact with another object, the apex is easily damaged because it is sharp, so the density of the apex of the corner is at least 0.8 g / cm 3 to prevent damage. It is desirable.
- the temperature (mold temperature) of the female mold 40 and the male mold 41 is appropriately set according to the fiber molded body to be manufactured, but in consideration of prevention of scorching of the fiber laminated body 10 ', etc., 100 to 250 ° C is preferred 120 to 200 ° C is more preferred.
- the pressure of the press molding by the female mold 40 and the male mold 41 is preferably 0.2 MPa to 10 MPa, more preferably 0.5 MPa to 5 MPa in consideration of surely crushing the thick portion.
- the pressure of press molding is the same as the material constituting the fiber molded body. It can also vary greatly with type, strength, etc.
- the valve 414 is open, and the moisture in the fiber laminate 10 'is sucked by the suction pump 412 through the gas-liquid flow passage and the discharge pipe 413 and discharged to the outside.
- the injection frame 20 is lowered by the vertical movement mechanism 21, and the papermaking portion 300 of the papermaking mold 30 ′ is included in the injection frame 20 again. Then, the fiber laminate is newly made in the same manner as in the paper making step.
- the suction from the flow pipe 403 is switched to the air injection by the compressor, and the female mold 40 is pulled up by the vertical movement mechanism 402 as shown in FIG. Then, after the suction by the suction pump 412 is stopped, the fiber molded body 11 ′ remaining on the male mold 41 side is removed from the male mold 41 to complete the production of the fiber molded body 11 ′. Further, the injection frame 20 is pulled up by the vertical movement mechanism 41, and the new fiber laminated body after the paper making process is moved to the heating process. In the manufacturing method of the present embodiment, such paper making and dry forming steps are repeatedly performed.
- a molded body with sharp corners formed at the intersection of two surfaces can be manufactured.
- the fiber molded body 11 'manufactured in this way is, as shown in Fig. 12 (a), when the flange portions 111 are opposed to each other. Since the apexes of the corners 113 of each other are sharp, for example, when two types of fiber molded bodies are butted together to form a bowl-making mold, and molten metal is supplied into the cavity to produce the bowl, FIG. As is clear from the force, no gaps are formed at the abutting portions of the corners, so that no residue is produced in the obtained article.
- the present invention is particularly suitable for a method for sharpening the apex of a corner formed at the intersection of two surface portions. This is because, as shown in FIG. 2, if the papermaking mold is provided with a groove, it is not necessary to separately form a thick portion. That is, a thick part can be formed by the groove during papermaking. In the present invention, the apex of the corner that is not formed at the intersection of the two surface portions can be sharpened. In this case, the wet papermaking method is used. After making a fiber laminate 10 ′ having a corner 103 ′ (see FIG. 21 (a)), a thick fiber portion 104 ′ is manually added to the corner 103 ′ in the vicinity of the corner 103 ′. (See FIG. 21 (b)), and then the fiber laminate is press-molded by the above-described method to obtain a fiber formed body 11 having sharp corner points 113 ′.
- the raw material slurry in addition to the raw material slurry in each of the above-described embodiments, those prepared so as to be compatible with the fiber molded body to be manufactured are used.
- the raw material slurry known slurries conventionally used in wet papermaking can be used.
- the fiber laminate in which the thick part is formed by papermaking and demolding is press-formed by the dry molding means as it is, but the thick part is formed.
- the fiber laminate can be stocked after drying without pressing, and can be press-molded again. Also in this case, the preferable wet state as described above is preferable.
- a force using a female mold (dry mold) of a dry molding means is used as a receiving mold, and the same as the female mold is used when transferring with the mold.
- a thick part may be formed.
- the female suction system is a single system.
- the suction system for sucking the outer edge of the flange portion of the fiber laminate is arranged separately from the suction systems of other parts.
- the force performed by suction through the gas-liquid flow passage as means for separating the outer edge portion of the flange portion from the papermaking mold, a stripper plate ordinarily used for a plastic mold It can also be separated by a mechanism such as an ejector pin.
- the mold parts (41a to 41c, etc.) divided like the male mold 41 shown in FIG. 22, and sharpening the corners of each mold part with a mechanical cage The male corner A (the rising part of the molding 410) can also be sharpened.
- the radius of curvature of the corner of the fiber molded body can be made substantially Omm.
- the corner A can be sharpened by machining even if the male die 41 is not made into a combination of divided mold parts, and the radius of curvature of the corner of the fiber molded body is 0.5 mm or less. be able to.
- the fiber laminate is press-molded to produce a fiber molded body having corners on the mating surface with other fiber molded bodies.
- a method of producing a fiber molded body having corners connected to a mating surface with another member after forming a fiber laminate including a fiber material and press forming the fiber laminate can also be employed.
- the other member is a product obtained by separately molding a thermoplastic resin such as polyethylene.
- Ratio of organic fiber (new newspaper) 4, inorganic fiber (carbon fiber) 4, inorganic powder (graphite powder) 76, thermosetting resin (phenol resin) 12, heat-expandable particle 4 (each value is part by mass) ) was dispersed in water to prepare a slurry having a solid concentration of about 3% by mass.
- a papermaking mold in which the base surface portion corresponding to the upper surface portion of the flange portion of the fiber laminate is provided at a position where the butt surface force is low and a recess is formed (the shape of the papermaking mold is shown in FIG.
- the fiber laminate is made with the same shape as shown) (thickness of the fiber laminate is lmn!
- a fiber laminate formed by bending the base was prepared, and further dried with a dry mold having a fluorocoating (for example, Teflon (registered trademark)) coating on the molding surface to prepare a fiber molded body.
- the pressure during drying was 3.8 MPa, and the temperature of the drying mold was 200 ° C.
- Example 2 Using the same raw material slurry as in Example 1, a fiber laminate was made with a paper making mold having no recesses, and dried according to the Example to produce a fiber molded body.
- Example 2 Using the same raw material slurry as in Example 2, a fiber laminate was made with a fine paper making mold with grooves, and dried according to Example 2 to produce a fiber shaped product.
- the method for producing a fiber molded body and the fiber molded intermediate of the present invention it is possible to produce a fiber molded body in which the apex of the corners of the mating surface is sharp. Further, according to the papermaking mold and the manufacturing apparatus of the present invention, the manufacturing method of the present invention can be suitably implemented. In the fiber molded body of the present invention, the apex of the corner formed at the intersection of the two surfaces of the fiber molded body is sharp.
- the method for producing a fiber molded article of the present invention is particularly suitable for producing the fiber molded article when the fiber molded article is used as a saddle shape, and in addition, a container having sharp corner apexes. ,road
- the present invention can also be applied to the production of various fiber molded products such as tools and parts.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Ceramic Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Paper (AREA)
- Mold Materials And Core Materials (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP05790564.8A EP1806454B1 (en) | 2004-10-12 | 2005-10-05 | Method and apparatus for producing fiber molded article, fiber molded precursor, and fiber molded article |
KR20067021620A KR100888315B1 (ko) | 2004-10-12 | 2005-10-05 | 섬유성형체의 제조방법 및 장치, 섬유성형중간체 및섬유성형체 |
ES05790564.8T ES2549078T3 (es) | 2004-10-12 | 2005-10-05 | Método y aparato para producir un artículo moldeado de fibra, precursor moldeado de fibra y artículo moldeado de fibra |
CNB2005800152041A CN100564672C (zh) | 2004-10-12 | 2005-10-05 | 纤维成形体的制造方法及装置、纤维成形中间体和纤维成形体 |
US10/593,182 US20080047676A1 (en) | 2004-10-12 | 2005-10-05 | Method And Apparatus For Producing Fiber Molded Article, Fiber Molded Precursor, And Fiber Molded Article |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2004-297604 | 2004-10-12 | ||
JP2004297604 | 2004-10-12 |
Publications (1)
Publication Number | Publication Date |
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WO2006040976A1 true WO2006040976A1 (ja) | 2006-04-20 |
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ID=36148271
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2005/018440 WO2006040976A1 (ja) | 2004-10-12 | 2005-10-05 | 繊維成形体の製造方法及び装置、繊維成形中間体並びに繊維成形体 |
Country Status (7)
Country | Link |
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US (1) | US20080047676A1 (ja) |
EP (1) | EP1806454B1 (ja) |
JP (1) | JP4601531B2 (ja) |
KR (1) | KR100888315B1 (ja) |
CN (1) | CN100564672C (ja) |
ES (1) | ES2549078T3 (ja) |
WO (1) | WO2006040976A1 (ja) |
Families Citing this family (13)
Publication number | Priority date | Publication date | Assignee | Title |
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JP4002200B2 (ja) * | 2002-03-13 | 2007-10-31 | 花王株式会社 | 鋳物製造用抄造部品 |
JP4675276B2 (ja) * | 2005-05-20 | 2011-04-20 | 花王株式会社 | 成形体 |
CN101316665B (zh) * | 2005-11-30 | 2011-04-27 | 花王株式会社 | 铸件制造用部件及其制造方法 |
JP2008081917A (ja) * | 2006-08-31 | 2008-04-10 | Kao Corp | 抄造型及び抄造成形体 |
WO2008026679A1 (fr) * | 2006-08-31 | 2008-03-06 | Kao Corporation | Moule de fabrication de papier et moulage de papier |
JP4980811B2 (ja) * | 2007-07-13 | 2012-07-18 | 花王株式会社 | 鋳型及び複合鋳型 |
KR100815263B1 (ko) * | 2007-10-31 | 2008-03-19 | 퍼스트세제 주식회사 | 펄프 몰딩기의 탈수공정용 하부금형 |
KR101260827B1 (ko) | 2011-12-30 | 2013-05-06 | 주식회사 명보 | 펄프 몰드 성형을 위한 메쉬틀이 부착된 펄프 몰드 성형금형 |
KR101260828B1 (ko) | 2011-12-30 | 2013-05-06 | 주식회사 명보 | 2단 리브 형태의 개구부를 갖는 펄프 몰드 성형품 및 그 제조방법 |
US10300762B2 (en) * | 2016-04-20 | 2019-05-28 | Toledo Molding & Die, Inc. | Method of making an acoustic automotive HVAC and AIS duct with a particle fiber slurry |
CN107881855B (zh) * | 2016-09-30 | 2019-07-26 | 英属维尔京群岛商茗享家股份有限公司 | 纸塑模用的模具及使用该模具的纸塑模成形方法 |
SE543321C2 (en) * | 2019-01-03 | 2020-11-24 | Celwise Ab | A pick-up press device and method of producing a 3D-molded product from a pulp slurry |
JP7453455B1 (ja) | 2023-07-12 | 2024-03-19 | 修 竹内 | 透かし模様付き金属板の製造方法 |
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DE59104750D1 (de) * | 1990-07-11 | 1995-04-06 | Alois Koch | Verfahren zur Herstellung eines Sarges aus geformtem Pulpestoff. |
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- 2005-10-04 JP JP2005291788A patent/JP4601531B2/ja not_active Expired - Fee Related
- 2005-10-05 WO PCT/JP2005/018440 patent/WO2006040976A1/ja active Application Filing
- 2005-10-05 KR KR20067021620A patent/KR100888315B1/ko active IP Right Grant
- 2005-10-05 CN CNB2005800152041A patent/CN100564672C/zh not_active Expired - Fee Related
- 2005-10-05 US US10/593,182 patent/US20080047676A1/en not_active Abandoned
- 2005-10-05 EP EP05790564.8A patent/EP1806454B1/en not_active Expired - Fee Related
- 2005-10-05 ES ES05790564.8T patent/ES2549078T3/es active Active
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JPH0686843U (ja) * | 1993-06-02 | 1994-12-20 | 清 喜多 | 紙等による鋳物用の鋳型 |
JPH08209600A (ja) * | 1994-11-28 | 1996-08-13 | Toomoku:Kk | 繊維材料から成る円筒体及びその製造方法 |
JP2000239998A (ja) * | 1998-02-23 | 2000-09-05 | Kao Corp | パルプモールド成形品の製造方法 |
JP2004195547A (ja) * | 2002-03-13 | 2004-07-15 | Kao Corp | 鋳物製造用抄造部品 |
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Also Published As
Publication number | Publication date |
---|---|
EP1806454A1 (en) | 2007-07-11 |
US20080047676A1 (en) | 2008-02-28 |
ES2549078T3 (es) | 2015-10-22 |
KR100888315B1 (ko) | 2009-03-11 |
CN1954121A (zh) | 2007-04-25 |
EP1806454B1 (en) | 2015-08-26 |
JP4601531B2 (ja) | 2010-12-22 |
EP1806454A4 (en) | 2012-06-06 |
CN100564672C (zh) | 2009-12-02 |
JP2006136939A (ja) | 2006-06-01 |
KR20070005683A (ko) | 2007-01-10 |
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