JPH10235768A - Fiberboard and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To combine a coconut fiber with a curable resin and add a bactericidal agent to produce a fiberboard which is stronger than a sizing board, has excellent moisture permeability, and has a good mold-proof property. obtain. SOLUTION: This is a fiberboard 1 obtained by compression-molding a fiber mat 2 made of coconut fibers to which a curable resin is attached, wherein 0.001 to 1 part by weight of an antibacterial agent is added to 100 parts by weight of coconut fibers. Was added. At least one surface and / or inside of the fiber mat 2 made of coconut fibers to which the curable resin is attached,
The fiberboard 1 was formed by compressing and molding a knitted or woven fabric 3 to which a curable resin was attached, and 0.001 to 1 part by weight of an antibacterial agent was added to 100 parts by weight of coconut fibers.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiberboard similar to a wood fiberboard, and more particularly to a fiberboard excellent in moisture permeability and strength and excellent in mold resistance.

[0002]

2. Description of the Related Art Conventionally, when a fiber-based heat insulating layer such as glass wool is formed in a wall of a wooden house, a ventilation layer is formed between the outer wall and the heat insulating layer in order to release water vapor in the room to the outside. Thus, the water vapor in the room that has passed through the heat insulating layer diffuses from under the eaves to the outside through the ventilation layer. In that case, a windproof layer that separates the ventilation layer and the heat insulating layer is required. The windproof layer has a function of retaining the heat insulating layer, but must have excellent moisture permeability so that water vapor can be smoothly transmitted to the ventilation layer.

[0003] Conventionally, as a material for forming the windproof layer,
For example, a nonwoven fabric made of polyethylene has been used, but if glass wool or the like is used for the heat insulating layer, there is a disadvantage that the nonwoven fabric swells and deforms due to the expansion force of the heat insulating layer and narrows the ventilation layer. This is particularly likely to occur when a large amount of glass wool or the like is packed in a cold region (see Building Construction Standard Specifications / Commentary JASS24 Insulation Work (edited by the Architectural Institute of Japan)). Therefore, a sizing board, which is a kind of soft fiberboard having a relatively low density and breathability among wood fiberboards, is applied to the outside of the heat insulating layer, and the ends thereof are pillars, studs, beams, girders, or braces. By fixing to a structural material such as (reinforcing material such as a rim or a braid), a windproof layer having a certain strength is formed.

[0004]

However, even though the above-mentioned conventional sheathing board can withstand the expansion force of the heat insulating layer, it does not have enough strength to function as a structural face material. Therefore, the strength of the structural part around the seasing board had to rely exclusively on the above-mentioned structural members other than the seasing board. Further, since the sizing board is made of wood fiber, it has a disadvantage that it is eroded by fungi such as mold and deteriorates.

[0005]

Means for Solving the Problems The present inventors have conducted intensive studies in order to solve these problems, and bonded coconut fibers with a curable resin and added 0.00% to 100 parts by weight of coconut fibers.
It has been found that by adding 1 to 1 part by weight of a bacteriostatic agent, a fiberboard excellent in strength and moisture permeability and excellent in antifungal property can be obtained, and the following invention has been achieved. That is, claim 1
Is a fiber board formed by compression molding a fiber mat made of coco fiber to which a curable resin is attached,
The present invention relates to a fiberboard obtained by adding 0.001 to 1 part by weight of a bactericidal agent to 00 parts by weight.

By laminating a knitted or nonwoven fabric in addition to the above fiber mat, the strength can be improved and the surface properties can be changed. That is, the invention of claim 2 is
A fiber board formed by compressing and forming a knitted or woven fabric to which a curable resin is attached on at least one surface and / or inside of a fiber mat made of palm fiber to which a curable resin is attached, wherein the weight of the palm fiber is 100%. 0.001 to 1 part
The present invention relates to a fiberboard obtained by adding a part by weight of an antibacterial agent.

A third aspect is the fiberboard according to the first or second aspect, wherein the coconut fibers are oil palm fibers.

[0008] Claim 4, in claim 2 or 3, knitted fabric, and a fiber board formed by hemp fibers having a basis weight of ^{100g / m 2 ~1200g / m 2} .

[0009] Claim 5 is the fiber board according to claim 1 to 4, the thickness of 3Mm～25mm, bending strength is ^{3N / mm 2 ~50N / mm 2} , and moisture permeation coefficient of 0 0.1 μg / (m ² · s · Pa) to 10 μg / (m ² · s
Pa).

A sixth aspect of the present invention is the fiberboard according to the first to fifth aspects, wherein the curable resin is an amino resin.

A seventh aspect of the present invention is the fiberboard according to the first to fifth aspects, wherein the curable resin is a phenol resin.

An eighth aspect is the fiberboard according to the first to sixth aspects, wherein the amino resin is a urea resin.

A ninth aspect of the present invention is the fiberboard according to the first to sixth aspects, wherein the amino resin is a melamine resin.

According to a tenth aspect, in the fiberboard according to the first to sixth aspects, the amino resin is a urea-melamine copolymer resin.

According to another aspect of the present invention, a fiber mat is formed from coconut fiber, a curable resin is adhered to the fiber mat, and 0.001 to 1 part by weight of a bactericidal agent is added to 100 parts by weight of coconut fiber. The method for producing a fiberboard according to claim 1, wherein the fiberboard is compression molded.

According to a twelfth aspect of the present invention, a fiber mat is formed from coconut fibers, a knitted or woven fabric is disposed on at least one surface or inside of the fiber mat, and a curable resin is adhered to the knitted or woven fabric. 0.001 to 1
The method for producing a fiberboard according to claim 2, wherein a part by weight of a bactericidal agent is added and compression molding is performed.

According to a thirteenth aspect of the present invention, a fiber mat is formed from coconut fiber, a curable resin is adhered to the fiber mat, and compression-molded.
The method for producing a fiberboard according to claim 1, wherein the fungicide is added in an amount of 01 to 1 part by weight.

According to a fourteenth aspect of the present invention, a fiber mat is formed from coconut fibers, a knitted or woven fabric is disposed on at least one surface or inside of the fiber mat, a curable resin is adhered to the knitted fabric or the nonwoven fabric, compression-molded, and 3. The method for producing a fiberboard according to claim 2, wherein 0.001 to 1 part by weight of an antibacterial agent is added to 100 parts by weight of the fiber.

[0019]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a fiberboard 1 according to the embodiment. The fiberboard 1 is formed by compression molding a fiber mat 2 made of coconut fibers to which a curable resin is attached.
It is obtained by adding 0.001 to 1 part by weight of a bactericidal agent to 00 parts by weight. This fiberboard 1 is excellent in strength and moisture permeability, and has good antifungal property.

The coconut fibers used in the present invention are coconut palm,
Oil palms, sago palms, date palms, sardines, nippa palms, sugar palms, pea palms, palms, palms,
Fibrous bark collected from palm plants such as black clogs,
Fibers such as petiole base fiber and mesocarp fiber, including fibers obtained by defibrating empty fruit clusters of oil palm. Also, a mixture of a plurality of types of coconut fibers is included.

The palm fiber has a diameter of about 100 to 600 μm.
Since the thickness of the fiber mat 2 is large, a gap having a size of, for example, about 100 μm to 5 mm, preferably about 200 μm to 3 mm is formed between the fibers, depending on the fiber packing density. Therefore, the moisture permeability of the fiber mat 2 is extremely good.

When the fiber mat 2 is compression-molded by adhering a curable resin to coconut fibers, the fiber board obtained is determined by the amount of the curable resin, the amount of the fiber mat 2 used, the compression ratio at the time of compression molding, and the like. The size of the gap between the fibers and the density of the gap can be variously changed. Thereby, the strength and moisture permeability of the fiberboard 1 can be controlled. For example, the gap of the fiberboard 1 is about 1 to 100 μm, usually 5 to 50 μm.
By setting the degree, it is possible to manufacture a good fiberboard 1 having air permeability but not allowing rain to pass. Therefore,
According to this fiberboard 1, an optimal windbreak layer can be formed according to the construction situation.

Further, the palm fiber has a diameter of about 100 to 6
The fiber board 1 is as thick as 00 μm, as long as about 5 to 30 cm, bent, and has a large entanglement between the fibers, so that the fiber board 1 has excellent holding power when nailed.

It is preferable to use oil palm palm fiber as the palm fiber. The palm fiber of the oil palm is obtained by defibrating empty fruit clusters of the oil palm. Oil palm palm fiber requires less labor for defibration and the like than other types of palm fiber, so that the energy required for production can be reduced and the cost can be reduced. For example, coconut palms need to be immersed in water for a long period of time to soften the coconut shells, and then to mechanically fibrillate them into a fibrous state, requiring a great deal of energy for a long period of time. On the other hand, oil palm disperses empty fruit clusters that are originally aggregated as fibrous,
There is no need for immersion in water, and very little energy is required for defibration. In addition, the palm fiber of oil palm is less dust-producing than the palm fiber of coconut palm, and it is preferable because the working environment is not deteriorated in handling.

The palm fiber of the oil palm is washed as needed before and after defibration to remove oil and odor. The palm fiber alone has high rigidity and a cross-sectional diameter of 10
The length is about 0 to 600 μm, and the length of the hair, that is, the length is about 5 to 30 cm. By defibrating the fiber, a high degree of entanglement can be expected. Moreover,
Palm oil can be exploited from oil palm fruit, but the empty fruit bunches remaining after harvesting the fruit are currently destined to be discarded without any specific use and are therefore available at low cost There is an advantage.

In order to form the fiber mat 2, the peel strength is increased by entanglement of the coconut fiber into a non-woven fabric or a three-dimensional knitted structure by needle punch or the like, and further, if necessary, by pressing or hot pressing. The fiber mat 2 is densified. The thickness of the fiber mat 2 is usually 5 mm when performing compression molding by pressing or hot pressing.
It is said that it is easy to use if it is set to about 20 mm, but it is needless to say that the present invention is not limited to this, and it may be set arbitrarily according to the application, or a plurality of sheets may be used.

The curable resin of the present invention includes a thermosetting resin and a reaction curable resin (room temperature curable resin). First, examples of the thermosetting resin include a phenol resin, an amino resin, and a diallyl phthalate resin (DAP resin). Phenolic resins include novolak resins (acid catalyst, excess phenol), resole resins (basic catalyst, excess formaldehyde), phenol-melamine copolymer resin, phenol-melamine-urea copolymer resin, alkylphenol-modified phenolic resin, rubber-modified phenolic resin There are denatured phenolic resins such as resin, and urea resin (urea resin), melamine resin, urea-melamine copolymer resin for amino resin,
There are benzoguanamine resin and acetoguanamine resin. Next, examples of the reaction curable resin (room temperature curable resin) include a furan resin, an alkyd resin, an unsaturated polyester resin, a urethane resin, an epoxy resin, a modified (modified) silicone resin, and a silicone resin. As the sizing agent or binder of the fiber mat 2, these curable resins are preferable from the viewpoint of dimensional accuracy, durability, strength and the like. However, although it is slightly inferior in physical properties, it is possible to partially use thermoplastic resins such as acrylic resins and styrene resins (particularly aqueous dispersions) having a binder effect and natural or synthetic rubber latex such as SBR. The curable resin of the invention is a concept including these. Among the above curable resins, a thermosetting resin is preferable from the viewpoint of curing time and productivity, and among them, a phenol resin and an amino resin are preferable. In the curable resin of the present invention, if necessary, a plasticizer,
Fillers, reinforcing materials, anti-sagging agents, coloring agents, anti-aging agents, adhesion promoters, curing catalysts, waxes, physical property modifiers and the like can be added. In addition, konjac, flour,
Starch and the like may be added. When the curable resin is an amino resin, there is an advantage that the price is low. Among them, urea resin is particularly inexpensive and has good adhesiveness. Also, when it is a melamine resin, it has particularly good water resistance, and when it is a urea-melamine copolymer resin, it is particularly inexpensive and has good water resistance. Further, when the curable resin is a phenol resin, the water resistance and the aging resistance are particularly good.

The amount of the curable resin used is preferably 5 to 100 parts by weight, more preferably 5 to 30 parts by weight, based on 100 parts by weight of the coconut fiber. More preferably, 10 to 30 parts by weight is exemplified. When the amount is less than 5 parts by weight, depending on the density, for example, when the density is 0.2 g / cm ³ , the bending strength is 3 N / m 3.
If it is lower than m ^2, and if it exceeds 100 parts by weight, depending on the density and thickness, for example, when the density is 1.5 g / cm ³ and the thickness is 9 mm, the moisture permeability coefficient is 0.1 μg / (m ² · s・ P
a), which is not preferable because the possibility of dew condensation increases when used as, for example, a windbreak layer.

The bactericides of the present invention include phenol-based bactericides, organotin-based bactericides, quaternary ammonium salt-based bactericides, imidazole-based bactericides, sulfone-based bactericides, and pyrrole-based bactericides. Fungicides, inorganic antibacterial agents and the like. Examples of this antibacterial agent include o-phenylphenol, p-phenylphenol, 2,4,6-trichlorophenol, 2,
4,6-tribromophenol, 2,5-dichloro-4
-Bromophenol, pentachlorophenol, monochloro-o-phenylphenol, 5-chloro-2-
(2,4-dichlorophenoxy) phenol, phenol derivatives such as p-chloro-m-xylenol, bis (tributyltin) oxide, bis (tributyltin) sulfide, tributyltin chloride, tributyltin fluoride, tributyltin phthalate tripropyltin fluoride, Organotin compounds such as tributyltin linoleate, tributyltin benzoate, triphenyltin hydroxide, tributyltin pentachlorophenolate, cetyldimethylethylammonium dibromide, N- (3-chloroallyl) heximinium chloride, 3- (trimethoxysilyl) ) Quaternary ammonium salts such as propyldimethyloctadecyl ammonium chloride, 2- (4-thiazolyl) benzimidazole, 1-
Imidazole derivatives such as (butylcarbamoyl) -2-benzimidazole methyl carbamate; sulfone derivatives such as N, N-dimethyl-N'phenyl-N '-(fluorodichloromethylthio) sulfamide; diiodomethyl-p-tolylsulfone; -(Trichloromethylthio) phthalimide, N-trichloromethylmercapto-
4-cyclohexene-1,2-dicarboximide, N
-(Fluorodichloromethylthio) phthalimide, N-
Pyrrole derivatives such as 1,1,2,2-tetrachloroethylthiotetrahydrophthalimide, sodium fluoride,
Inorganic compounds such as copper sulfate are included. Among the antibacterial agents, 2- (4-thiazolyl) benzimidazole, N, N-dimethyl-N'phenyl-N'-
(Fluorodichloromethylthio) sulfamide, N-
(Fluorodichloromethylthio) phthalimide is preferred.

The amount of the antibacterial agent used is 0.001 to 1 part by weight, preferably 0.01 part by weight, per 100 parts by weight of coconut fiber.
It is preferably from 0.5 to 0.5 part by weight. More preferably 0.0
1 to 0.1 part by weight. 0.00 parts of antibacterial agent
If the amount is less than 1 part by weight, the occurrence of mold is recognized, for example, in a situation where mold is likely to be generated by getting wet with water. On the other hand, if the amount exceeds 1 part by weight, physical properties such as strength decrease are caused as compared with the case where no antibacterial agent is used, and the cost is undesirably increased.

The thickness of the fiberboard 1 of the present invention is 3 mm to 25 m.
m is preferable, and 9-20 mm is more preferable. Moreover density fiberboard is preferably ^{0.2g / cm 3 ~1.5g / cm 3} , preferably further ^{0.3g / cm 3 ~1g / cm 3} , and most preferably, 0.35g / cm ³ ~0. 7g /
cm ³ . If the density of the fiberboard is less than 0.2 g / cm ³ , for example, the flexural strength becomes less than 3 N / mm ² and JIS
The fiberboard of A-5905 does not satisfy the quality as a seasing board, and the fiberboard exceeding 1.5 g / cm ³ has a high possibility of compressive failure of the fiberboard due to an increase in compression force. However, it is not preferable because it is difficult to obtain by heating and compression, and it becomes too heavy to deteriorate the handling properties such as carrying. Also, the basis weight of the fiberboard 1 is, for example, when the thickness of the fiberboard 1 is 9 mm, the density is 0.2 kg / cm ³ and the basis weight is 1.8 kg / m ² , and when the density is 1.5 g / cm ³ , the basis weight is 13 0.5 kg / m ² .

This fiberboard 1 has a high strength, and is adjusted to the density and the curable resin amount of the fiberboard 1 so that the fiberboard 1 has the same bending strength and wet bending strength as a 5 to 30 type medium fiberboard. While it can be of the order or higher, it is also possible to obtain a value whose moisture permeability is equal to or higher than that of the seasing board. Regarding both of these properties, for example, the bending strength is 3 N / mm ^{2 to} 50 N / mm ² , preferably 4 N / mm ^2.
４０40 N / mm ² , more preferably 5-30 N / mm ²
And a moisture permeability coefficient of 0.1 μg / (m ² · s · Pa) or more
10 μg / (m ² · s · Pa), preferably 0.2 μg
^{/ (M 2 · s · Pa} ) ~8μg / (m 2 · s · Pa), more preferably ^{0.5μg / (m 2 · s ·} Pa) ~5μg
/ (M ² · s · Pa).

In the method of manufacturing the fiberboard 1, first, a fiber mat 2 is formed from coconut fibers. The mechanism used in this step is, for example, as shown in FIG. 2, a required number of hoppers 5 are provided in series in the belt traveling direction above the upstream side of the belt conveyor 4, and a needle punch device 6 is provided downstream of the hopper 5. Spray guns 7, 7 are installed above and below a belt conveyor 4 downstream of the spray gun. Palm fiber is put in the hopper 5, and a curable resin and an antibacterial agent are supplied under pressure to the spray gun 7. After the coconut fibers are dropped and supplied from the respective hoppers 5 onto the belt conveyor 4 simultaneously with the operation of the belt conveyor 4, the fiber mat 2 is formed by performing a process of needle-punching the coconut fibers by the needle punching device 6 to entangle the coconut fibers. Further, the curable resin and the antibacterial agent are jetted and supplied from the spray guns 7 and 7 toward the fiber mat 2. Next, the fiberboard 1 is formed by hot compression molding using a hot press or the like. The thermal compression molding includes a method of continuous molding by a thermocompression roller or a belt press, and a method of repeated molding by a batch method using a single-stage or multi-stage press. Further, the curable resin and the antibacterial agent are attached to the fibers by spraying with a spray gun 7 or the like, but may be attached by dipping the fiber mat 2 in a mixture of the curable resin and the antibacterial agent. The antibacterial agent may be added by spraying or brushing after adhering the curable resin to the fiber mat 2 and thermocompression molding, or may be sprayed or mixed with a paint or the like by mixing the antibacterial agent. You may add by brushing etc. Note that the heat treatment at the time of compression molding may be performed as needed, and is not an essential step.

In addition to the continuous molding method, there is also a method of molding one sheet at a time. In such a case, a hardening resin and an antibacterial agent are adhered to the fiber mat 2 to form a mold, which is then subjected to heat compression molding by a hot press or the like.

As described above, the fiber mat 2 is formed from coconut fiber, a curable resin is adhered to the fiber mat 2, a bactericide is added, and the fiber mat 2 is compressed. A mat 2 is formed, and the fiber mat 2
Alternatively, a method may be employed in which a curable resin is adhered to the mixture, compression-molded, and then a bactericide is added.

In the above embodiment, since a large gap is formed between fibers in the fiber mat 2 of coconut fibers, when the curable resin is supplied by spraying or dipping, the curable resin is applied to all the fibers through the gap. It adheres evenly, which makes the strength distribution of the fiberboard 1 uniform. The same can be said for the antibacterial agent. When the antibacterial agent is supplied by spraying or dipping, the antibacterial agent uniformly adheres to all the fibers through the above-mentioned gaps. Is good.

Therefore, in the fiber board 1 of the above embodiment, the palm fibers are strongly bonded to each other by the curable resin, and the density is increased by compression molding, so that uniform and high strength can be obtained. Since a relatively large gap is formed between the fibers, the moisture permeability is extremely good. Moreover, an excellent antifungal property can be obtained by the antibacterial agent attached to the inside. Therefore, if the windproof layer is formed by the fiber board 1, the water vapor can be smoothly transmitted to the ventilation layer due to the high moisture permeability, and the heat insulation layer can be stably held due to the high strength. The structural portion around the windbreak layer can be reinforced by the fiberboard 1. In addition, even if fungi such as mold adhere, the erosion does not cause deterioration.

Further, as another embodiment of the present invention, a knitted or woven fabric 3 having a curable resin adhered thereto is provided on at least one surface and / or inside of a fiber mat 2 made of coconut fibers having a curable resin adhered thereto. A fiberboard placed and compression molded, wherein 0.001 to 1 part by weight per 100 parts by weight of coconut fiber
Some are obtained by adding parts by weight of a bactericidal agent. The fiber board 1 shown in FIG. 4 is an example in which a knitted fabric 3 to which a curable resin is attached is arranged on both sides and inside of a fiber mat 2. As the knitted fabric 3, as shown in FIG. 3, a cloth obtained by knitting hemp yarns twisted hemp fibers vertically and horizontally is exemplified. Here, the hemp includes those that take the skin fibers such as jute, flax, kenaf, and ambassador, and those that take the tissue fibers such as manila, sisal, New Zealand and Mauricias. Hemp fibers are fibers obtained by defibrating these hemp. Knitted fabrics include jute cloth, which is a cloth formed of jute. In addition, non-woven fabrics include non-woven fabrics made by drying a web from hemp fibers, hardening with an adhesive such as latex of natural rubber, drying and finishing, and thin non-woven fabrics formed by a wet papermaking method. And paper formed by wet papermaking. These knitted and woven fabrics have air permeability and are excellent in moisture permeability. In a single fiber board, a knitted fabric and a nonwoven fabric may be used in combination of two or more.

Since the knitted fabric 3 is formed by knitting hemp fiber or the like having a high tensile strength and a high modulus of elasticity, the fabric itself exhibits excellent tensile strength and a high modulus of elasticity. The nonwoven fabric 3 has a lower strength than the knitted fabric 3 such as hemp, so the knitted fabric 3 is more preferable, but has a function as a holding material for the curable resin. Although the fibers constituting the nonwoven fabric 3 are not particularly limited,
Considering the bonding force with the fiber mat 2, natural fibers are preferable, and nylon, polypropylene, polyethylene,
Synthetic fibers such as polyester may be mixed if necessary.

When the knitted fabric 3 is a hemp cloth, examples of the weave structure include plain weave, twill weave, satin weave, and nanaco weave (regular,
(Including irregular ones), etc., among which plain weave and twill weave are particularly preferred. The knitting structure is selected from flat knitting, rubber knitting and the like. As an example of the yarn used here, it is preferable to select from jute counts of 7.5 to 40 in terms of availability and the like. The basis weight is 100 g / m ^{2 to} 120.
About 0 g / m ² is preferable. Furthermore, 100 g / m ² -1
000 g / m ² is preferred, most preferably 100 g / m ²
m ^{2 to} 600 g / m ² . If the basis weight is less than 100 g / m ² , for example, the dimensional change in the longitudinal direction at the time of water absorption exceeds 0.5%, and the quality of the sizing board in the fiberboard of JIS-A-5905 will not be satisfied, and 1200 g / m 2 will be satisfied. ^If it exceeds ² , the cost will increase despite the increase in dimensional stability and increase in the reinforcing effect, which is not preferable. In addition, the number of hemp cloths 3 to be laminated on the fiber mat 2 depends on the dimensional stability required by the portion where the fiberboard 1 is used,
The basis weight and the number of layers can be selected in combination depending on physical properties such as strength, but 5 to 50 parts by weight is preferable for 100 parts by weight of coconut fiber. The amount is more preferably 5 to 30 parts by weight, most preferably 10 to 25 parts by weight. If the weight part of the hemp cloth 3 is less than 5 parts by weight, for example, the dimensional change in the longitudinal direction at the time of water absorption exceeds 0.5%, and if it exceeds 50 parts by weight, the cost increases, which is not preferable.

The knitted or woven fabric 3 is made of a fiber mat 2
, Those arranged only on both surfaces or one surface of the fiber mat 2, those arranged on both surfaces or one surface of the fiber mat 2, and those arranged inside the fiber mat 2. further,
When the knitted woven fabric or nonwoven fabric 3 is arranged inside the fiber mat 2, the knitted woven fabric or nonwoven fabric 3 is made into a plurality of sheets, and the knitted woven fabric or nonwoven fabric 3 and the coconut fiber of the fiber mat 2 are alternately stacked and arranged in a multilayer form. Including those that did. Also, knitted or non-woven fabric 3
Is arranged inside the fiber mat 2, if a treatment such as needle punching is performed in this state,
The fiber mat 2 and the fibers of the knitted fabric or the nonwoven fabric 3 are well entangled with each other, so that the peel strength of the fiber board 1 is increased, and the bending strength and the flexural modulus are improved.

Since the knitted or woven fabric 3 is strongly bonded to the fiber mat 2 via the curable resin, the strength of the fiber board 1 is increased. That is, when the knitted fabric or the nonwoven fabric 3 is arranged on the surface of the fiber mat 2, particularly on both surfaces, a so-called sandwich structure (a structure in which the upper and lower parts of the main body structure are reinforced with a material having strength or rigidity higher than that of the main body structure) becomes The bending strength and the bending elastic modulus of No. 1 are increased. On the other hand, when the knitted or nonwoven fabric 3 is disposed inside the fiber mat 2, the tensile strength and tensile modulus, shear strength and shear modulus, and in-plane compressive strength (compressive force in a plane stress state) of the fiber board 1 are measured. ) And the in-plane compression elastic modulus (the elastic modulus when receiving a compressive force in a plane stress state).

Further, when the knitted fabric 3 is formed of hemp fibers such as hemp cloth, the dimensional change during water absorption and moisture absorption is small. Dimensional change is small, water absorption,
This is preferable because the decrease in strength during moisture absorption is small.

The curable resin is used as a sizing agent or binder for the fiber mat 2, imparts strength to the knitted or nonwoven fabric 3 itself, and binds the knitted or nonwoven fabric 3 to the fiber mat 2. Serves as a binder for the entire fiberboard 1 or as a component for imparting strength.

As a method of manufacturing the fiber board 1, a fiber mat 2 is formed from coconut fibers, and a knitted or nonwoven fabric 3 is arranged on at least one surface or inside of the fiber mat 2, and a curable resin is adhered thereto. There is a manufacturing method in which a bactericide is added and compression molding is performed. In addition, fiber mat 2
There is also a manufacturing method in which a knitted or woven fabric or nonwoven fabric 3 is disposed on at least one surface or inside of the fiber mat 2, a curable resin is adhered to the knitted woven fabric or the nonwoven fabric 3, compression-molded, and then a bactericidal agent is added.

Therefore, in the above-described other embodiment, the bending strength, the bending elastic modulus, and the like of the fiberboard 1 can be further increased as compared with the previous embodiment, and the strength can be improved. In addition, the surface properties can be changed, and the use of the fiber board 1 does not require finishing, and the finishing material retainability is improved even when a finishing material is applied. In this case, if the knitted or woven fabric 3 is made of a material having high moisture permeability such as hemp fiber, high moisture permeability of the entire fiber board can be obtained without impairing the excellent moisture permeability of the fiber mat 2. Therefore, if the windproof layer is formed from the fiberboard 1, the water vapor can be smoothly transmitted to the ventilation layer due to the high moisture permeability, and the heat insulation layer can be stably held due to the higher strength. The structure around the windbreak layer can be reinforced. In addition, even if fungi such as mold adhere, the erosion does not cause deterioration.

When vegetable natural fibers such as hemp fiber and bamboo fiber are mixed with the above fiber mat 2, the diameter of the palm fiber is about 100 to 600 μm, whereas the diameter of the hemp fiber is about 100 to 600 μm. Because the diameter of bamboo fiber is about 5 to 30 μm and the diameter of bamboo fiber is 10 to 200 μm, it is thought that hemp fiber, bamboo fiber and other vegetable natural fibers are entangled at intersections of palm fibers and the like, and the bonding strength between palm fibers is considered to increase. .

Also, a fiber mat 2, a knitted or nonwoven fabric 3
However, when both are vegetable natural fibers, the unevenness of the surface is larger than that of artificial fibers and the like, so that the entanglement strength between the fibers is higher than that of artificial fibers, and the so-called anchor effect (the adhesive is a void on the surface of the material). Of the curable resin due to the fact that it penetrates and solidifies and acts like a nail or a wedge).

Further, if it is necessary to further improve the water resistance of the knitted or woven fabric 3,
May be applied to the surface of the substrate. Further, a flame retardant, a colorant, a preservative, an anti-termitic agent and the like may be applied as necessary.

Further, in the above embodiment, only the fiberboard 1 having a rectangular shape in a front view and a substantially constant thickness has been described. Good. In that case, only the final shape is different, and the description items regarding the fiberboard 1 of the above embodiment can be applied as they are, and the same operation and effect can be obtained.

[0051]

Next, examples of the present invention will be described together with comparative examples.

Example 1 3.8 kg of urea resin
/ M ² of oil palm palm fiber was sprayed onto a fiber mat by a spray method, and 10 parts by weight of urea resin in solid content was attached to 100 parts by weight of palm fiber. Next, the fiber mat was heated and pressed by a press machine at 170 ° C. for 10 minutes to obtain a fiber board having a thickness of 9 mm and a density of 0.46 / cm 3. Hokuko Chemical Industries New Hoxter E50A [2-
(4-thiazolyl) benzimidazole-containing antibacterial agent] was applied by brushing to 0.05 parts by weight of solids with respect to 100 parts by weight of coconut fiber, and then water was removed by drying. The fiberboard obtained has a bending strength of 14.5 N / mm ² , 4
The moisture permeability coefficient at 0 ° C.-90% is 2.6 μg / (m ² · s · P
a). Further, after spraying the same amount of water as the weight of the fiberboard onto the fiberboard with a sprayer, the fiberboard was sealed in a polyethylene bag and left at 23 ° C. for one week, but no mold was observed. The bending strength was measured according to JIS-A-590.
5 according to the measurement method for the fiberboard. The moisture permeability coefficient is JIS-Z-
[0208] The measurement was performed according to the moisture permeability test method of the moisture-proof packaging material.

Example 2 Melamine resin weight: 3.3 k
A fiber mat composed of g / m ² oil palm palm fiber was sprayed by a spray method, and 10 parts by weight of a melamine resin in solid content was attached to 100 parts by weight of palm fiber. Next, melamine resin was added to ^two jute cloths having a basis weight of 0.32 kg / m ^{2 at} a solid content concentration of 100 parts by weight of the jute cloth.
0 parts by weight were adhered. Subsequently, the jute cloth, the fiber mat, and the jute cloth were stacked in this order, and the fiber mat and the jute cloth were placed in a press at 170 ° C.-1.
Heat press under the condition of 0 minutes, thickness 9mm, density 0.48
/ Cm ³ of fiberboard was obtained. 1 is added to the obtained fiberboard with water.
Hokusei Chemical New Hoxter E5 diluted 1:00
OA (2- (4-thiazolyl) benzimidazole-containing antibacterial agent) was applied by brushing to 0.1 part by weight of a solid content with respect to 100 parts by weight of coconut fiber, and then water was removed by drying. The fiberboard obtained has a flexural strength of 15.8 N / m.
m ² , 40 ° C.-90% moisture permeability coefficient is 2.4 μg / (m ² ·
s · Pa). Further, water was sprayed on the fiberboard with a sprayer, then sealed in a polyethylene bag, and allowed to stand at 23 ° C. for 1 week, but no mold was observed.

<Comparative Example 1> 3.8 kg of urea resin
/ M ² of oil palm palm fiber was sprayed on a fiber mat by a spray method, and 10 parts by weight of urea resin was adhered to 100 parts by weight of oil palm fiber at a solid content. Next, the fiber mat was heated and pressed by a press machine at 170 ° C. for 10 minutes to obtain a fiber board having a thickness of 9 mm and a density of 0.46 / cm ³ . The obtained fiberboard has a bending strength of 14.0 N /
mm ² , the moisture permeability coefficient at 40 ° C.-90% is 2.6 μg / (m ²
S · Pa). After spraying water on the fiberboard with a sprayer, the fiberboard was sealed in a polyethylene bag,
After standing for a week, the occurrence of mold was observed.

<Comparative Example 2> The melamine resin had a basis weight of 3.3k.
A fiber mat composed of g / m ² oil palm palm fiber was sprayed by a spray method, and 10 parts by weight of a melamine resin in solid content was attached to 100 parts by weight of palm fiber. Next, melamine resin was added to ^two jute cloths having a basis weight of 0.32 kg / m ^{2 at} a solid content concentration of 100 parts by weight of the jute cloth.
0 parts by weight were adhered. Subsequently, the jute cloth, the fiber mat, and the jute cloth were stacked in this order, and the fiber mat and the jute cloth were placed in a press at 170 ° C.-1.
Heat press under the condition of 0 minutes, thickness 9mm, density 0.48
/ Cm ³ of fiberboard was obtained. The obtained fiberboard has a bending strength of 16.3 N / mm ² , a temperature of 40 ° C.-90%, and a moisture permeability coefficient of 2.
It was 4 μg / (m ² · s · Pa). Further, after spraying the same amount of water as the weight of the fiberboard onto the fiberboard with a sprayer, the fiberboard was sealed in a polyethylene bag, and allowed to stand at 23 ° C. for 1 week. As a result, generation of mold was observed. Table 1 shows Examples 1 and 2
And the number of parts of the antibacterial agent of Comparative Examples 1 and 2, the bending strength of the fiberboard,
Shows the moisture permeability coefficient and mold generation status. As shown in Table 1, the antibacterial agent was added in an amount of 0.05 to 100 parts by weight of the oil palm fiber.
No mold generation was observed in any of the fiberboard coated with parts by weight and the fiberboard coated with 0.1 parts by weight. Also, the bending strength and the moisture permeability coefficient were good.

[0056]

[Table 1]

[0057]

As described above, the fiberboard according to claim 1 is a fiberboard obtained by compression-molding a fiber mat made of coconut fibers to which a curable resin is adhered, and based on 100 parts by weight of coconut fibers. Since the fiberboard contains 0.001 to 1 part by weight of an antibacterial agent, excellent strength and moisture permeability can be obtained, and high antifungal properties can be obtained even inside the fiberboard. In the fiberboard according to the second aspect, a knitted or woven fabric is laminated, so that the strength can be further improved and the surface properties can be changed. Therefore, if a windproof layer is formed of these fiberboards, indoor water vapor can be smoothly transmitted through the ventilation layer, the heat insulation layer can be stably held, and even if fungi such as mold adhere, erosion occurs. No deterioration occurs.

The use of the fiberboard of the present invention is not limited to a windproof layer, but is excellent in strength, moisture permeability and mold resistance. Tatami materials, roof materials, ceiling materials, house interior materials, interior materials, architectural insulation materials, rim materials, sound insulation materials, sound absorbing materials, cushioning materials,
It can also be used as a shock absorbing material, a concrete form material, a loading pallet, a vehicle interior material such as an automobile, a vehicle interior base material such as an automobile, a furniture material, and the like. According to the fiberboard of claim 3, oil palm fiber is used for the palm fiber, so that in addition to the above effects, the energy required for production can be reduced, and the cost can be reduced.

According to the fourth aspect, since the knitted fabric is formed of hemp fiber, the strength is greatly improved, and the dimensional change upon water absorption and moisture absorption is reduced, so that the fiber is most suitable for forming the windproof layer. A plate is obtained.

According to the fifth aspect, the thickness is from 3 mm to
25 mm and a bending strength of 3 N / mm ² to 50
N / mm ² and a moisture permeability coefficient of 0.1 μg / (m ²
s · Pa) to 10 μg / (m ² · s · Pa), so that the balance between strength and moisture permeability is particularly excellent, which is more preferable.

When the curable resin is an amino resin, the cost of the fiberboard can be reduced. When the phenolic resin is used, the water resistance and the aging resistance can be improved. When the urea resin is used, the cost of the fiberboard can be reduced and the adhesiveness can be improved. When a melamine resin is used, the water resistance can be improved. When the urea-melamine copolymer resin is used, the cost of the fiberboard can be reduced and the water resistance can be improved. Since the phenol resin and the amino resin have a short curing time, the productivity of the fiberboard can be improved.

According to claims 11 to 14, it was possible to propose a production method suitable for producing the fiberboard with high production efficiency.

[Brief description of the drawings]

FIG. 1 is a perspective view of a fiber board according to an embodiment;

FIG. 2 is an explanatory view showing a method for producing the fiber mat of the embodiment;

FIG. 3 is an enlarged perspective view showing an example of a knitted fabric used in another embodiment.

FIG. 4 is a cross-sectional view of the other embodiment.

[Description of Signs] 1 Fiber board 2 Fiber mat 3 Hemp cloth (Knitted fabric) 4 Belt conveyor 5 Hopper 6 Needle punch device 7 Spray gun

Claims (14)

[Claims] 1. A fiber board obtained by compression-molding a fiber mat made of palm fiber to which a curable resin is attached, wherein 0.001 to 1 part by weight of a bactericidal agent is added to 100 parts by weight of palm fiber. Fiberboard made. 2. A fiber board which is compression-molded by arranging a knitted or nonwoven fabric to which a curable resin is attached on at least one surface and / or inside a fiber mat made of coconut fibers to which a curable resin is attached. And a fiberboard obtained by adding 0.001 to 1 part by weight of a bactericidal agent to 100 parts by weight of palm fiber. 3. The fiberboard according to claim 1, wherein the coconut fiber is an oily coconut fiber. 4. A knitted fabric having a basis weight of 100 g / m ^{2 to} 120 g / m ^2.
Fiber plate according to claim 2 or 3 are formed by hemp fibers 0 g / m ^2. 5. A thickness of 3 mm to 25 mm,
Bending strength is ^{3N / mm 2 ~50N / mm 2} , and moisture permeation coefficient of ^{0.1μg / (m 2 · s ·} Pa) ~10μg /
Fiberboard according to any one of claims 1 to 4 is a ^{(m 2 · s · Pa)} . 6. The method according to claim 1, wherein the curable resin is an amino resin.
The fiberboard according to any one of claims 1 to 5. 7. The fiberboard according to claim 1, wherein the curable resin is a phenol resin. 8. The method according to claim 1, wherein the amino resin is a urea resin.
The fiberboard according to any one of Items 1 to 6. 9. The fiberboard according to claim 1, wherein the amino resin is a melamine resin. 10. The fiberboard according to claim 1, wherein the amino resin is a urea-melamine copolymer resin. 11. A fiber mat formed by coconut fibers,
A curable resin is adhered to the fiber mat, and coconut fibers 10
The method for producing a fiberboard according to claim 1, wherein 0.001 to 1 part by weight of a bactericidal agent is added to 0 part by weight and compression molding is performed. 12. A fiber mat is formed by coconut fibers,
A knitted fabric or a nonwoven fabric is arranged on at least one surface or inside of the fiber mat, a curable resin is attached to these, and a bactericidal agent of 0.001 to 1 part by weight is added to 100 parts by weight of coconut fiber, The method for producing a fiberboard according to claim 2, wherein the fiberboard is compression molded. 13. A fiber mat formed by coconut fibers,
2. The method for producing a fiberboard according to claim 1, wherein a curable resin is adhered to the fiber mat, compression-molded, and then 0.001 to 1 part by weight of an antibacterial agent is added to 100 parts by weight of coconut fiber. 14. A fiber mat formed by coconut fibers,
A knitted or woven fabric is arranged on at least one surface or inside of the fiber mat, a curable resin is adhered to the knitted or woven fabric, and compression-molded.
The method for producing a fiberboard according to claim 2, wherein the bactericide is added in an amount of 01 to 1 part by weight.