JPH1058470A - Plate or molded body and method for producing the same - Google Patents

Abstract

(57) [Summary] (Modifications required) [Problem] Assuming the use of vegetable natural fibers, among them, palm fibers with large gaps formed between thick fibers are collected, and the fibers are securely fixed with resin. In contrast, a knitted or woven fabric made of vegetable natural fibers such as hemp fibers having an appropriate tensile strength and tensile elastic modulus, a sheet made of flakes such as a nonwoven fabric or bamboo is integrated with the aqueous resin composition. The present invention provides a plate-like body or a molded body having both excellent moisture permeability and high strength by reinforcing by reinforcement, and having high strength in a wet state. SOLUTION: At least one surface of a fiber mat 2 made of palm fiber mixed with vegetable natural fiber if necessary and / or
Alternatively, a sheet-like material 3 formed by arranging a knitted woven fabric, a nonwoven fabric, or a sheet-like material flakes made of vegetable natural fibers, adhering an aqueous resin composition, and heat-compressing and molding the inside. Body 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plate-like body similar to a wood fiberboard and a molded body obtained by molding the same into a predetermined shape, and particularly exhibits excellent performance in both moisture permeability and strength. The present invention relates to a plate-like body or a molded body having high strength in a wet state.

[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, polyethylene non-woven fabric has been used, but if glass wool or the like is used for the heat-insulating layer, the non-woven fabric swells and deforms due to the expansion force of the heat-insulating layer, narrowing and sometimes closing 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 the standard specifications for construction work, JASS24 insulation work (edited by the Architectural Institute of Japan)). Therefore, among the fiberboards, a sheathing board, which is a kind of a soft fiberboard having relatively small density and air permeability, is applied to the outside of the heat insulating layer, and the end side thereof is a structure such as a pillar, a stud, a beam, a girder or a brace. By fixing to a material, a windproof layer having a certain strength is formed.

[0004]

However, even though the above-mentioned conventional sizing board can withstand the expansion force of the heat insulating layer,
It does not have enough strength to function as a structural face material itself. Therefore, the strength of the structural portion around the seasing board had to rely exclusively on the above-mentioned structural material other than the seasing board. Further, the seasing board has a disadvantage that the strength in a wet state is low.

The present invention has been made in view of such a point, and an object of the present invention is to use a vegetable natural fiber having a bonding strength to a resin which is superior to that of an artificial fiber. By collecting palm fibers, which form large gaps between thick fibers, the fibers are securely fixed to each other with resin, and vegetable fiber such as hemp fiber having an appropriate tensile strength and tensile elasticity. A sheet having both excellent moisture permeability and high strength, and a high strength in a wet state by integrating and reinforcing a sheet-like material made of a thin piece such as a knitted woven fabric, a nonwoven fabric or a bamboo with the aqueous resin composition. It is to provide a shape or a molded object. In addition, the manufacturing method is also proposed.

[0006]

Means for Solving the Problems The present inventors have conducted intensive studies in order to solve the above-mentioned problems, and as a resin composition,
A water-based resin in which the state before adhesion is an aqueous solution or a water-dispersed state, the weight ratio of water to the resin composition is 0.4 to 6.0, and / or the viscosity at 25 ° C. is 0.02 to 100 poise. By using the composition, it exhibits excellent affinity and permeability to the surface of vegetable natural fiber such as coconut fiber and forms an effective adhesive coating on the fiber surface, and is excellent in both strength and moisture permeability The present invention has been found to exhibit high performance, particularly high strength when wet, and facilitate the work of adhering the resin composition. That is, the present invention
If necessary, at least one surface and / or interior of a fiber mat composed of palm fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, a knitted woven fabric, nonwoven fabric or bamboo made of vegetable natural fiber such as hemp fiber A sheet-like material composed of flakes is arranged, and the state before being attached thereto is an aqueous solution or a water-dispersed state, the weight ratio of water to the resin composition is 0.4 to 6.0 and / or at 25 ° C. The present invention relates to a plate-like body or a molded body obtained by adhering an aqueous resin composition having a viscosity of 0.02 to 100 poise, heating and compressing and molding.

[0007] The present invention also relates to the above-mentioned plate-like body or molded article using oil palm fiber as palm fiber.

Further, the present invention relates to the above-mentioned plate-like body or molded body using hemp cloth as a knitted fabric.

[0009] The present invention further comprises hemp fiber,
Vegetable natural fibers such as bamboo fiber are mixed to form a fiber mat, and at least one surface and / or inside of the fiber mat is a woven fabric, a nonwoven fabric, or a bamboo or the like made of vegetable natural fibers such as hemp fiber. A sheet-like material is disposed, the state before being attached thereto is an aqueous solution or a water-dispersed state, the weight ratio of water to the resin composition is 0.4 to 6.0, and / or the viscosity at 25 ° C. The present invention relates to a method for producing a plate-like body or a molded body, which is formed by adhering an aqueous resin composition having a particle size of 0.02 to 100 poise, heating and compressing.

The plate-like or molded article of the present invention may be used as a windproof layer used for forming a ventilation layer on the outer wall of a house as described above, but is not limited thereto. For example, home interior materials, interior base materials, roof base materials, ceiling materials,
Floor materials, floor base materials, tatami floors, structural structural insulation materials, sound absorbing materials,
As a sound insulating material, a shock absorbing material, a cushioning material, or a building material such as a rim,
It can be used for all building material applications where plywood, glulam, particle board, etc. are used. Furthermore, it can also be used as a material for concrete forms, pallets, packaging materials, interior materials for vehicles such as automobiles, interior base materials, exterior materials and the like.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION A plate-like body according to a first embodiment of the present invention is provided on at least one surface and / or inside of a fiber mat composed of coconut fibers mixed with vegetable natural fibers as necessary. A knitted fabric made of fibers is arranged, and the state before being attached thereto is an aqueous solution or a water-dispersed state, the weight ratio of water to the resin composition is 0.4 to 6.0, and / or the viscosity at 25 ° C. Is formed by applying a water-based resin composition having a particle size of 0.02 to 100 poise, heating and compressing the mixture into a plate shape. This plate-shaped body has both excellent moisture permeability and high strength, and particularly has high strength in a wet state. Instead of the knitted fabric, a sheet-like material made of a thin piece of nonwoven fabric or bamboo may be used.

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.

Since coconut fibers have a large diameter of about 100 to 600 μm, when formed into a fiber mat, 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. It is formed. Therefore, the moisture permeability of the fiber mat is extremely good.

The size of the gaps and the density of the gaps between the fibers of the obtained plate-like body vary depending on the amount of resin when the resin composition is adhered to the fiber mat and the degree of compression during the molding. Can be done. Thereby, the moisture permeability of the plate can be controlled. For example, by setting the gap between the plate-like bodies to about 1 to 100 μm, usually about 5 to 50 μm, it is possible to produce a good plate-like body having air permeability but not allowing rain to pass.

Further, the palm fiber has a diameter of about 100 to 6
Since the sheet is as thick as 00 μm, the length is as long as about 5 to 30 cm, the sheet is bent and the entanglement between the fibers is large, the plate-like body is excellent in holding force when nailed.

It is preferable to use oil palm fiber as the palm fiber. This oil palm fiber is obtained by defibrating empty fruit clusters of oil palm. Oil 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 fibers require a large amount of energy for a long period of time to be immersed in water for a long period of time to soften the coconut shell and then mechanically defibrated into a fibrous state.
On the other hand, in the case of oil palm, since the empty fruit clusters which are originally fibrous and aggregated are defibrated, there is no need for immersion in water, and very little energy is required for defibration. In addition, oil palm fibers are less dust-producing than coco fiber and are preferred because handling thereof does not deteriorate the working environment.

The oil palm fiber is optionally washed before and after defibration to remove oil and odor. The oil palm fiber alone has a high rigidity and a cross-sectional diameter of 100 to 6
It is about 00 μm and its hair foot, that is, the length is about 5
It is about 30 cm, and by defibrating the fiber, a high degree of entanglement can be expected. Moreover, oil palm oil can be exploited from the oil palm fruit, but the empty fruit bunch remaining after harvesting this fruit has no specific use at present and is usually destined to be discarded, so it is low cost. It has the advantage of being available.

Further, this fiber mat may be mixed with vegetable natural fibers such as hemp fiber and bamboo fiber, if necessary. Here, vegetable natural fibers include hemp fibers that are hemp fibrillated fibers, bamboo fibers that are fibrillated young bamboos, sugarcane fibers, hechima fibers, pineapple fibers, banana fibers, koulyan fibers, fibers obtained from Inawara, and wood fibers. There is no particular limitation as long as it is a fiber obtained from a natural plant. These are also
They may be mixed alone, or two or more kinds may be mixed simultaneously.

When vegetable natural fibers such as hemp fiber and bamboo fiber are mixed with the fiber mat, the diameter of the palm fiber is about 1
Since the diameter of the hemp fiber is about 5 to 30 μm and the diameter of the bamboo fiber is 10 to 200 μm, the natural vegetable fiber such as the hemp fiber and the bamboo fiber crosses the palm fiber at the intersection of the palm fiber. It is considered that the entanglement of the palm fibers increases the bonding strength between the palm fibers.

In order to form a fiber mat, the peel strength is increased by entanglement of the coconut fiber into a non-woven fabric or a three-dimensional knitted structure by a needle punch or the like, and the fiber is further pressed by a press or a hot press if necessary. Make the mat denser. The thickness of the fiber mat is usually 5 mm to 2 mm.
It is said that it is easy to use when the thickness is about 0 mm, but it is needless to say that the fiber mat is not limited to this and may be set arbitrarily according to the application.
g / m ² ~6kg / m ² can be mentioned. Also, a plurality of sheets may be used.

The knitted fabric includes, for example, a cloth obtained by knitting hemp yarn obtained by fibrillating hemp fibers and twisting hemp yarns vertically and horizontally, and thus includes a jute cloth which is a cloth formed of jute. In addition, the nonwoven fabric is made of a hemp fiber obtained by fibrillating hemp, dry-formed into a web, hardened with an adhesive such as a latex of natural rubber, and dried and finished to form a nonwoven fabric or a thin nonwoven fabric formed by wet papermaking. And paper formed by fibrillating wood fibers and wet papermaking. In addition, the sheet-like material includes a material obtained by knitting a thin strip-like thin piece cut out of a bamboo material or the like vertically and horizontally (actually, it is close to a weave). These knitted and woven fabrics, nonwoven fabrics and sheet materials have air permeability and are excellent in moisture permeability. The vegetable natural fiber used for the knitted fabric, the nonwoven fabric, and the sheet may be a mixture of a plurality of types of vegetable natural fibers. Also, a knitted fabric, a nonwoven fabric, and a sheet-like material may be used in combination of two or more.

In the plate-like body of the present invention, the fiber mat, knitted woven fabric, non-woven fabric and sheet-like material are all vegetable natural fibers and have larger irregularities on the surface than artificial fibers. The so-called anchor effect (the fact that the adhesive penetrates into the voids on the surface of the material and solidifies and acts like a nail or wedge) together with high entanglement strength between the fibers
Has the advantage of being excellent in bonding strength with the resin composition.

Since the knitted fabric or sheet-like material is knitted or woven with hemp fibers or bamboo flakes having a high tensile strength and tensile elasticity, the material itself exhibits excellent tensile strength and tensile elasticity. Further, the nonwoven fabric has a lower strength than a knitted fabric such as hemp or a sheet material such as bamboo, so that a knitted fabric or a sheet material is preferable, but has a function as a resin holding material. If necessary, synthetic fibers such as nylon, polypropylene, polyethylene and polyester may be mixed with the natural fibers forming the nonwoven fabric.

The knitted woven fabric, nonwoven fabric or sheet is strongly bonded to the fiber mat via the resin composition, so that the strength of the plate is increased. That is, when the knitted fabric, nonwoven fabric or sheet-like material is arranged on the surface of the fiber mat, especially on both surfaces, a so-called sandwich structure (a structure in which the upper and lower parts of the main structure are reinforced with a material having strength or rigidity higher than that of the main structure) is used, The flexural strength and flexural modulus of the plate-like body are increased. On the other hand, when the knitted fabric, nonwoven fabric or sheet is placed inside the fiber mat, the tensile strength and tensile modulus, shear strength and shear modulus of the plate, and in-plane compressive strength (in plane stress) The strength when receiving a compressive force) and the in-plane compressive modulus (the elastic modulus when receiving a compressive force in a plane stress state) increase. Furthermore, since the knitted fabric or sheet-like material has a small dimensional change during water absorption and moisture absorption, when placed on the surface or inside of the fiber mat, the dimensional change during water absorption and moisture absorption of the plate-like body becomes small, and the water absorption and moisture absorption are reduced. Is less reduced in strength.

Further, textiles, basis weight of the nonwoven fabric or sheet is 10g / m ² ~1500g / m ^2, the strength and moisture permeability, preferably from the viewpoint of shape stability. More preferably, 10
^{0g / m 2 ~600g / m 2} , more preferably 150 g /
m ^{2 to} 350 g / m ² . When the basis weight is 10 g / m ² or less, the above-described reinforcing effects such as bending strength and compressive strength are reduced. On the other hand, if the basis weight is 1500 g / m ² or more, the plate-like body is dragged by the deformation of the knitted woven fabric, the non-woven fabric, and the sheet-like material, and the warpage and twist after molding are increased.

Particularly, in the present invention, a knitted fabric using hemp fiber is preferable. Here, the hemp includes those that take the skin fibers such as hemp (burlap), hemp, flax, mao, and ambassadors, and those that take the tissue fibers such as Manila, sisal, New Zealand and Mauricias. Hemp fibers refer to fibers obtained from these hemp. Since hemp (burlap) fiber is called jute, hemp fiber here includes jute.

Examples of hemp knitted and woven structures include plain weave,
It is preferable to select from twill weave, satin weave, nanako weave (including regular and irregular), and among them, plain weave and twill weave are particularly preferred. The knitting structure is selected from flat knitting, rubber knitting and the like.
The driving density is selected according to the combination of the weave structure and the yarn count.

When it is necessary to further improve the water resistance of the knitted fabric, nonwoven fabric or sheet, silicon or the like may be applied to the surface of the knitted fabric, nonwoven fabric or sheet. Further, a flame retardant, a coloring agent, a preservative, a termiticide, a fungicide and the like may be applied as required.

As an example of the resin composition of the present invention, 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-urea copolymer resin, phenol-melamine-urea copolymer resin, alkylphenol There are denatured phenol resins such as denatured phenol resins and rubber denatured phenol resins, and amino resins include urea resins (urea resins), melamine resins, urea-melamine copolymer resins, benzoguanamine resins, and acetoguanamine resins. Next, as the reaction curable resin (room temperature curable resin), furan resin,
Examples include alkyd resins, unsaturated polyester resins, urethane resins, epoxy resins, modified (modified) silicone resins, and silicone resins. Further, as a sizing agent or a binder for the fiber mat, these resin compositions are preferable in terms of dimensional accuracy, durability, strength, and the like. However,
Acrylic, styrene, etc. thermoplastic resin with binder effect (especially aqueous dispersion)
Also, natural or synthetic rubber latex such as SBR can be partially used, and the resin composition of the present invention is a concept including these.

Of these resin compositions, thermosetting resins are preferred from the viewpoint of curing time and productivity, and among them, phenol resins and amino resins are preferred.

The above-mentioned resin composition is in an aqueous solution or water-dispersed state before being adhered, and is adhered to a fiber mat and a knitted or woven fabric, a nonwoven fabric or a sheet in this state. By being in an aqueous solution or a water-dispersed state, affinity and permeability with the surface of the vegetable natural fiber are improved, and a film effective with respect to adhesiveness and water resistance can be formed on the fiber surface.

Furthermore, the weight ratio of water to the resin composition in the aqueous solution or aqueous dispersion of the resin composition before adhesion is 0.1.
It is preferably from 4 to 6.0, more preferably from 0.55 to 4.0. When the weight ratio is less than 0.4, usually the viscosity becomes too high, the resin is hard to spread evenly on the surface of the vegetable natural fiber, the effective film formation is insufficient, and the adhesion between the fibers becomes insufficient. This makes the operation of attaching to the fiber difficult. When the weight ratio exceeds 6.0, a large amount of water is simultaneously attached to the vegetable natural fiber together with the resin, and the heat is removed by the latent heat of evaporation of the water during the heat compression molding, whereby the adhesive strength is reduced, The strength of the shaped body is weakened, the strength in a wet state is reduced, and the effect of dilution with water is reduced. Further, it is not preferable because more energy is required after drying than after drying.

The viscosity at 25 ° C. of the aqueous solution or dispersion of the resin composition before adhesion is preferably from 0.02 to 100 poise, and more preferably from 0.05 to 10 poise. If the viscosity at 25 ° C. exceeds 100 poise, the fluidity is insufficient, the resin is difficult to spread uniformly on the surface of the vegetable natural fiber, the effective film formation is insufficient, and the adhesion between the fibers is insufficient. At the same time, the operation of adhering to the fiber is difficult, and the adhering state becomes uneven. On the other hand, if it is less than 0.02 poise, the fluidity is too high, and when the resin is adhered to the fiber mat, the resin liquid flows and the adhesion efficiency is reduced.

The amount of the resin composition to be used cannot be specified unconditionally because it varies depending on the physical properties required for the plate-like body, but for example, 5 to 1 based on the weight of each of the fiber mat and hemp cloth.
00% by weight, preferably 5 to 50% by weight, more preferably 10 to 30% by weight. The amount of the resin composition used for the fiber mat and the hemp cloth may be the same weight% or different weight% with respect to each weight. Further, the strength of the plate-like body can be changed by changing the amount of the resin composition used for the hemp cloth. That is, when the amount of the resin composition used for the hemp cloth increases, the strength of the plate-like body can be increased. For example, the amount of the resin composition used for hemp cloth is 5 to 500%, preferably 5 to 150%. When the amount of the resin composition used is less than 5%, the laminating effect of the hemp cloth is hardly exhibited, and when it exceeds 500%, the effect of increasing the amount is hardly obtained.

The water-based resin composition of the present invention may contain a plasticizer, a filler, a reinforcing material, an anti-sagging agent, a coloring agent, an anti-aging agent, an adhesion promoter, a curing catalyst, a physical property modifier and the like, if necessary. I can do it. In addition, konjac, flour,
Starch and the like may be added.

The method for attaching the resin composition is not particularly limited. Since a large gap is formed between the fibers in the fiber mat of the coconut fiber, when the resin composition is supplied by spraying or dipping, the resin composition uniformly adheres to all the fibers through the gap, thereby forming a plate-like shape. The intensity distribution of the body becomes uniform.

The thickness of the plate of the present invention is 3 mm to 25 m.
m is preferable, and 9 mm to 20 mm is more preferable. If the thickness of the plate-like body is less than 3 mm, sufficient bending strength cannot be obtained, and if it exceeds 25 mm, the thickness of the wall is increased in terms of use and is not practical in use. The density of the plate is 0.
2 g / cm ^{3 to} 1 g / cm ³ is preferable, and 0.3 g / cm ³ is more preferable.
/ Cm ³ ~0.7g / cm ³ are preferred, most preferably ^{0.35g / cm 3 ~0.6g / cm 3} . The basis weight of the plate-shaped body is, for example, when the thickness of the plate-shaped body 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 g / cm ³ , the basis weight is 9 kg / cm ^3. m ² .
When the density is less than 0.2 g / cm ³ , the strength of the plate is not sufficient. When the density exceeds 1 g / cm ³ , the moisture permeability is reduced, and the weight of the plate becomes too heavy and handling becomes poor.

FIG. 1 shows the plate-like body 1 of the first embodiment. Reference numeral 2 denotes a fiber mat, and reference numeral 3 denotes a knitted fabric disposed on both surfaces of the fiber mat 2. FIG. 1 illustrates the knitted fabric 3 with hemp cloth, which is shown in FIG.

The manufacturing method of the above-mentioned plate-like body 1 is as follows.
In addition, if necessary, hemp fibers are defibrated, and the unit cross-sectional diameter is about 5 to 5.
Fiber having a length of about 5 to 30 cm is obtained.
The defibrated coconut fibers include fibers having a larger cross-sectional diameter, thinner fibers, longer fibers and shorter fibers, but can be used as they are. At this time, since the natural length of the coconut fiber is about 5 to 30 cm, there is no particular need to process it. Next, the fibrous mat 2 is formed by mixing the fibrillated palm fiber with the fibrous natural fiber such as hemp fiber and bamboo fiber, if necessary. The mechanism used in this step is, for example, as shown in FIG. 3, a plurality of first, second,... Plural hoppers 12, 12,. The spray gun 13 is disposed so as to be directed to the vicinity of the outlet 12, and a heat pressure roller 14 is provided downstream of the hopper 12 so as to face the belt conveyor 11. In each hopper 12, mixed fibers obtained by mixing palm fibers, hemp fibers, bamboo fibers, and the like at an appropriate ratio are put, and an aqueous solution or aqueous dispersion of the resin composition is supplied under pressure to the spray guns 13, 13,. . And
At the same time as the operation of the belt conveyor 11, the mixed fibers are dropped and supplied from each hopper 12 onto the belt conveyor 11, and
By spraying and supplying the aqueous solution or the aqueous dispersion of the resin composition from each spray gun 13 toward the mixed fiber, the lowermost first layer is formed on the belt conveyor 11 by the mixed fiber from the first hopper 12. The fiber mat 2 is formed by forming a second layer thereon by using the mixed fibers from the second hopper 12, forming a fiber layer thereon in turn, and then press-molding with a heat-pressing roller 14. I do. Of course, when fibers are not mixed, only coconut fibers may be supplied to all hoppers 12, and hopper 12 and spray gun 13 may be supplied.
May be one. Further, the spray gun 13 may be arranged downstream of the hopper 12. In addition, the first, second,
By changing the characteristics (mixing ratio, fiber thickness, fiber length) of the fibers supplied to the plurality of hoppers 12, 12,..., The characteristics of the fibers constituting each layer can be changed. In particular, in the case where thick palm fibers are arranged in the center of the fiber mat 2 and thin palm fibers are arranged on both surfaces, the contact density of the fibers on the surface side of the fiber mat 2 is increased, so that a plate-like body to be molded from this is obtained. 1 is good.

Next, hemp cloths 3, 3 are arranged on both sides of the fiber mat 2, a resin composition is adhered to them, and the fiber mat is subjected to heat compression molding. The mechanism used in this step also pulls the fiber mat 2 forward, for example, as shown in FIG.
While hemp cloths 3 and 3 are continuously supplied from above and below,
The spray guns 13 are arranged at the merging portions, respectively, and the heat-pressing rollers 15, 15 are opposed to each other downstream of the spray guns. An aqueous solution or aqueous dispersion of the resin composition is supplied under pressure to the spray guns 13, 13,.... Then, while pulling the fiber mat 2 forward, an aqueous solution or aqueous dispersion of the resin composition is jetted and supplied from each spray gun 13, and then the plate-like body 1 is formed by heating and pressing with the heat-pressing rollers 15, 15. Is continuously molded.

In addition to the continuous molding method, there is also a method of molding one sheet at a time. In such a case, the resin composition is adhered to the fiber mat 2 and molded, the hemp cloths 3 and 3 are applied to the fiber mat 2 via the resin composition, and the fiber mat 2 is subjected to heat compression molding by hot pressing or the like.

The plate 1 may be formed one by one as follows. First, a resin composition is added to vegetable natural fibers such as coconut fibers and stirred to adhere the resin composition. Next, a hemp cloth 3 coated with a resin composition is laid on the bottom of a mold (not shown), the above fibers are filled from above, and finally the hemp cloth 3 is laid. This is molded with a predetermined thickness and a predetermined density by a hot press or the like, and
Get.

Further, in the above embodiment, the fiber mat 2
In the case of molding, the case where the defibrated vegetable natural fibers are directly filled in the formwork has been described, but the fibers are woven into a cloth, and the cloth is impregnated with the resin composition.
This may be laminated in multiple layers and molded. Thereby, a large physical strength can be obtained without impairing the moisture permeability.

Although the resin composition is applied to the fibers by spraying with a spray gun 13 or the like, the fibers may be applied by immersing the fibers in an aqueous solution of the resin composition or the like.

The resin composition is used as a sizing agent or a binder for the fiber mat 2, imparts strength to the hemp cloth itself, a binder for the hemp cloth 3 and the fiber mat 2, and furthermore, the entire plate-like body. Acts as a binder or a component for imparting strength.

Therefore, in the plate-like body 1 of the first embodiment, the fiber mat 2 is a coconut fiber mixed with vegetable natural fibers such as hemp fiber and bamboo fiber as necessary.
Is made of hemp fibers and has a larger surface irregularity than artificial fibers and the like, so that the fibers have a higher entanglement strength than the artificial fibers and have a higher bonding strength with the resin composition due to the so-called anchor effect. Moreover, while the diameter of the palm fiber is about 100 to 600 μm, for example, the hemp fiber is as thin as about 5 to 30 μm, so that the vegetable natural fiber such as hemp fiber is entangled at the intersection of the palm fiber, The bond strength between palm fibers is increased. Further, bamboo fiber or the like has a flat shape and is rigid, so that mixing with coconut fiber has the meaning of improving strength and the like. Therefore, if the windproof layer is formed by the plate-like body 1, the heat-insulating layer can be stably held with high strength, and the plate-like body 1 can reinforce the structural portion around the windproof layer. .

The palm fiber has a diameter of about 100 to 60.
Since it is as thick as 0 μm, when the fiber mat 2 is used, for example, 100 μm to 5 m
Since a gap having a size of about m is formed, the moisture permeability of the fiber mat 2 is extremely good. The hemp cloth 3 also has excellent breathability since the stitches have air permeability. Accordingly, the plate-like body 1 of the present invention obtained from these materials has various strengths and moisture permeability depending on the amount of the resin composition, the amount of the fiber mat 2 and the amount of the hemp cloth 3 used, and the compression ratio at the time of compression molding. You can get things. Therefore, this plate-like body 1 functions as an excellent windproof layer.

Since the hemp cloth 3 is made of knitted hemp fibers or the like having a moderately high tensile strength and tensile elastic modulus, the hemp cloth 3 itself exhibits excellent tensile strength and tensile elastic modulus. Then, since the hemp cloth 3 is strongly bonded to the fiber mat 2 via the resin composition, the strength of the plate-like body 1 is increased. That is,
When hemp cloth 3 is arranged on both sides of fiber mat 2,
It becomes a so-called sandwich structure, and the bending strength and the bending elastic modulus of the plate-like body 1 are increased. Further, the hemp cloth 3 has a small dimensional change upon water absorption and moisture absorption.
When placed on both sides of the plate, water absorption of the plate-like body, dimensional change at the time of moisture absorption,
This is preferable because the strength decrease during water absorption and moisture absorption is small. Therefore, the plate-like body 1 functions as a structural surface material, and can reinforce the structural portion around the windbreak layer.

Further, since the resin composition can form an effective film on the fiber mat 2 and the fiber surface of the knitted woven fabric, nonwoven fabric or sheet material 3 with respect to adhesiveness and water resistance, the strength of the plate-like body 1, especially in the wet state Strength can be improved. In addition, since it can be attached to a fiber mat or the like in an aqueous solution or a water-dispersed state, the attaching operation is simple.

Although the knitted fabric, nonwoven fabric or sheet material 3 is arranged on both surfaces of the fiber mat 2, in the present invention, the knitted fabric, nonwoven fabric or sheet material 3 is arranged only on one surface of the fiber mat 2. , A knitted woven fabric, a nonwoven fabric or a sheet-like material 3 disposed inside the fiber mat 2, a knitted woven fabric, a nonwoven fabric or a sheet-like material 3 disposed on both surfaces or one surface and inside the fiber mat 2. It is a thing.

As an example, FIG. 4 shows a plate-like body 1 according to a second embodiment. This plate-like body 1 is a fiber mat 2
And a knitted woven fabric, nonwoven fabric or sheet-like material 3 disposed inside the fiber mat 2 and a knitted woven fabric, nonwoven fabric or sheet-like material 3 disposed on both surfaces of the fiber mat 2, respectively. It is formed in a thick plate shape.

The present invention further provides a knitted woven fabric, a nonwoven fabric or a sheet-like material 3 when the knitted woven fabric, the nonwoven fabric or the sheet-like material 3 is disposed inside the fiber mat 2. Includes those in which the object 3 and the coconut fiber of the fiber mat 2 are alternately stacked and arranged in a multilayer shape. Further, when the knitted fabric, nonwoven fabric or sheet-like material 3 is arranged inside the fiber mat 2, if a treatment such as needle punching is performed in such a state, the fiber mat 2, the knitted fabric,
The fibers of the nonwoven fabric or the sheet-like material 3 are well entangled with each other, so that the peel strength of the plate-like body is increased, and the bending strength and the flexural modulus are improved.

When the knitted woven fabric, nonwoven fabric or sheet material 3 is placed inside the fiber mat 2, the tensile strength and tensile modulus, shear strength and shear modulus, and in-plane compressive strength and Because the in-plane compression modulus increases,
The plate-like body 1 functions as a structural surface material, and can reinforce the structural portion around the windbreak layer.

Further, in the first embodiment, only the knitted fabric 3 is used, but the knitted fabric, nonwoven fabric or sheet-like material 3 may be used in combination with the sheet-like material 3 formed by cutting thin pieces cut out of bamboo or the like.
When a plurality of are used, these may be used in an appropriate combination.

Further, in the above embodiment, only a plate-like body 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 plate-like body of the above embodiment can be applied as they are, and the same operation and effect can be obtained.

[0056]

EXAMPLES Next, examples of the plate-shaped body of the present invention will be described together with comparative examples.

<Example 1> Fibers were entangled by needle punching using a defibrated oil palm fiber to prepare a fiber mat. Then, a weight ratio of water to the resin composition (hereinafter referred to as water / water ratio) was 1.22 kg / m ^2.
A urea resin (aqueous solution type, solid content: 62%) adjusted to 1.43 was sprayed by a spray method, and a urea resin having a solid content of 10% by weight relative to the mat weight was adhered. . Next, use a jute cloth (basis weight 32)
(0 g / m ² ) A urea resin having a water / resin composition weight ratio of 3.73 was applied to two sheets by a spray method so that the solid content was 10% based on the weight of the jute cloth. Then, after jute cloth, two oil palm fiber mats, and jute cloth were stacked in this order, they were heated and pressed by a press machine at 165 ° C. for 10 minutes to obtain a plate having a thickness of 9.0 mm. . The obtained plate was evaluated by the following evaluation items and methods. The flexural strength was measured according to JIS A 5906 measuring method for medium fiberboard. The moisture permeability coefficient is JIS Z 020
8 Measured according to the moisture permeability test method of the moisture-proof packaging material.
The bending strength in the wet state was measured by immersing the molded plate in water at 25 ° C. for 24 hours, and immediately after taking out the same, in the same manner as the bending strength measurement. The evaluation results are shown in Table 1.

<Example 2> In the same manner as in Example 1, using a mat having a basis weight of 1.21 kg / m ² , a urea resin having a water / resin composition weight ratio of 0.61 was added to a solid weight based on the weight of the mat. And 10% by weight. Next, weight 3
20 g / m ² of jute cloth with a solid content of 10
A urea resin having a water / resin composition weight ratio of 3.73 was adhered so as to be in a weight percentage to form a plate-like body. 9.2m thick
m was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1.

Comparative Example 1 In the same manner as in Example 1, a mat having a basis weight of 1.18 kg / m ² was used, and a urea resin having a water / resin composition weight ratio of 6.64 was used. The urea resin was adhered so as to be 10% by weight per minute. Next, a urea resin having a water / resin composition weight ratio of 6.64 was adhered to a jute cloth having a basis weight of 320 g / m ^{2 so} as to have a solid content of 10% by weight to form a plate-like body. A plate having a thickness of 8.8 mm was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1.

<Comparative Example 2> In the same manner as in Example 1, a mat having a basis weight of 1.18 kg / m ² was used, and powdered phenol resin (melting point: 85 ° C) was used so as to be 10% by weight based on the weight of the mat. Was attached. Next, the same phenol resin was added at 10% by weight to a jute cloth having a basis weight of 320 g / m ^2.
To form a plate-like body. Thickness 9.0
mm was obtained. The obtained plate-like body was obtained in Example 1.
The evaluation was performed in the same manner as described above.

<Comparative Example 3> A commercially available sheathing board Asadas D manufactured by Daiken Kogyo was evaluated for physical properties in the same manner as in Example 1. The results are shown in Table 1. The used sheathing board had a thickness of 11.5 mm.

[0062]

[Table 1]

Examples 1 and 2 and Comparative Examples 1 to 1 shown in Table 1
As is clear from the result of No. 3, the state before adhesion is an aqueous solution or a water-dispersed state, and the water / resin composition weight ratio is 0.4 to 0.4.
It can be seen that the plate-like body using the aqueous resin composition at 6.0 exhibits excellent performance in both strength and moisture permeability, and particularly has high strength when wet.

<Example 3> Using a defibrated oil palm fiber, the fiber was entangled with a needle punch to prepare a fiber mat. Then, a urea resin having a viscosity of 1.85 poise at 25 ° C. (aqueous solution type, solid content 65%, U-75 manufactured by Mitsui Toatsu Co., Ltd.) was applied to the fiber mat having a basis weight of 1.21 kg / m ^2.
5) was sprayed by a spray method, and 10% by weight of a urea resin in terms of a solid content relative to a mat weight was adhered. Next, a urea resin having a viscosity of 0.05 poise at 25 ° C. was applied to two pieces of jute cloth (basis weight: 320 g / m ² ) by a spray method so that the solid content was 10% by weight based on the weight of the jute cloth. . Then, after jute cloth, two oil palm fiber mats, and jute cloth were stacked in this order, they were heated and pressed by a press machine at 165 ° C. for 10 minutes to obtain a plate having a thickness of 9.0 mm. . The obtained plate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 2.

Example 4 In the same manner as in Example 3, a phenol resin having a viscosity of 0.10 poise at 25 ° C. (aqueous solution, solid content of 4%) was used using a mat having a basis weight of 1.21 kg / m ^2.
0%, PL-222 manufactured by Mitsui Toatsu Co., Ltd.) was applied so that the solid content was 10% by weight based on the weight of the mat. Next, the viscosity at 25 ° C. is adjusted to 0.05% so that the solid content becomes 10% by weight based on a jute cloth having a basis weight of 320 g / m ^2.
A plate-like body was formed by adhering Poise's phenolic resin. A 9.2 mm thick plate was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 2.

Comparative Example 4 In the same manner as in Example 3, a mat having a basis weight of 1.21 kg / m ² was used, and a urea resin whose viscosity at 25 ° C. was adjusted to 0.015 poise was used, based on the weight of the mat. 10% by weight of a urea resin was adhered on a solid basis. Next, a urea resin whose viscosity at 25 ° C. was adjusted to 0.015 poise was adhered to a jute cloth having a basis weight of 320 g / m ² so as to have a solid content of 10% by weight to form a plate-like body. A plate having a thickness of 9.0 mm was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 2.

<Comparative Example 5> In the same manner as in Example 3, a mat having a basis weight of 1.21 kg / m ² was used, and a phenol resin whose viscosity at 25 ° C was adjusted to 0.015 poise was used. 10% by weight of a urea resin was adhered on a solid basis. Next, a phenol resin whose viscosity at 25 ° C. was adjusted to 0.015 poise was adhered to a jute cloth having a basis weight of 320 g / m ² so as to have a solid content of 10% by weight to form a plate-like body. A 9.1 mm thick plate was obtained. The obtained plate was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 2.

[0068]

[Table 2]

Examples 3 and 4 and Comparative Examples 3 to 4 shown in Table 2
As is clear from the result of No. 5, the state before adhesion is an aqueous solution or an aqueous dispersion state, and the viscosity at 25 ° C. is 0.02 to 10
It can be seen that the plate-shaped body using the aqueous resin composition having 0 poise exhibits excellent performance in both strength and moisture permeability, and particularly has high strength when wet.

[0070]

As described above, the plate-like body or the molded article according to the first aspect of the present invention has a structure in which at least one surface and / or inside of a fiber mat composed of coconut fibers mixed with vegetable natural fibers is used, if necessary. A knitted or woven fabric made of natural fibers, a nonwoven fabric, or a sheet made of flakes is arranged, and the state before attachment is an aqueous solution or a water-dispersed state, and the weight ratio of water to the resin composition is 0.4 to 6.0. And / or a water-based resin composition having a viscosity at 25 ° C. of 0.02 to 100 poise is adhered thereto, and is obtained by molding by heating and compression, so that excellent moisture permeability and high strength are obtained. It also has a high strength, especially in a wet state, and can easily perform the work of attaching the resin composition. Therefore, if, for example, a windbreak layer is formed from this plate-like body or molded body, it is easy to perform the construction, and it is possible to smoothly transmit indoor water vapor through the ventilation layer and to stably hold the heat insulation layer. In addition, it is possible to reinforce the structural portion around the windbreak layer by the plate-like body or the molded body.

According to the plate-like body or the molded body of the second aspect, the energy required for production can be reduced, and the cost can be reduced.

According to the third aspect, it is possible to obtain a knitted woven fabric having excellent bonding strength with the resin composition and high tensile strength, and to provide a plate-like body or a molded body having higher strength.

According to claim 4, a production method suitable for the plate-like body or the molded body could be proposed.

[Brief description of the drawings]

FIG. 1 is a sectional view of a plate-like body according to a first embodiment;

FIG. 2 is an enlarged perspective view illustrating an example of a knitted fabric according to the first embodiment;

FIG. 3 is an explanatory view showing a method for producing the fiber mat of the first embodiment;

FIG. 4 is a cross-sectional view of a plate-like body according to a second embodiment.

[Explanation of symbols]

 Reference Signs List 1 plate-like body 2 fiber mat 3 hemp cloth (knitted fabric), non-woven fabric, sheet-like material

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location // B29K 101: 10 105: 06 (72) Inventor Kenji Kurimoto 2-9 Maikodai, Tarumizu-ku, Kobe-shi No. 30 1219

Claims (4)

[Claims] 1. A knitted woven fabric, a nonwoven fabric or a sheet made of flakes made of vegetable natural fibers is arranged on at least one surface and / or inside of a fiber mat made of palm fibers mixed with vegetable natural fibers as required. The state before adhesion to these is an aqueous solution or an aqueous dispersion state, the weight ratio of water to the resin composition is 0.4 to 6.0, and / or the viscosity at 25 ° C is 0.02 to 100 poise. A plate-like body or a molded body obtained by attaching a certain water-based resin composition, and compressing by heating. 2. The plate-like or molded article according to claim 1, wherein the palm fiber is an oil palm fiber. 3. The plate-like body or the molded article according to claim 1, wherein the knitted woven fabric composed of vegetable natural fibers is a hemp cloth composed of hemp fibers. 4. A fiber mat formed by mixing planted natural fibers with defibrated palm fibers as required, and a knitted fabric made of vegetable natural fibers is provided on at least one surface and / or inside of the fiber mat. A sheet-like material made of a nonwoven fabric or a flake is arranged, and the state before being attached thereto is an aqueous solution or an aqueous dispersion state, and the weight ratio of water to the resin composition is 0.4 to
6.0 and / or a viscosity at 25 ° C. of 0.02 to 1
The method for producing a plate-like body or a molded article according to any one of claims 1 to 3, wherein the aqueous resin composition having a volume of 00 poise is adhered, and the mixture is molded by heating and compression.