JPH10175204A - Fiberboard and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make waterproofness excellent while excellent moisture permeability and high strength are jointly provided by a method wherein a specific ratio to raw material of wax is added to a fiberboard wherein knitting textile composed of a specific ratio to coconut fiber of plant fiber is laminated, curable resin is stuck thereto, and they are compression molded. SOLUTION: An amount of knitting textile to be laminated is 5-50 pts.wt. to 100 pts.wt. of coconut fiber, and most preferably 10-25 pts.wt. Curable resin is used as a binder of fiber mat. Its used amount is 5-100 pts.wt. of raw material fiber, and most preferably 10-30 pts.wt. Wax is solid wax or wax emulsion as a form to be used. Further, its additional amount is 0.01-5 pts.wt. as a wax solid content to 100 pts.wt. of raw material fiber, and most preferably 0.1-2 pts.wt.

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 waterproofness.

[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 relatively low density and air permeability among the wood fiberboards, is applied to the outside of the heat insulating layer, and the ends thereof are pillars, studs, beams, beams, braces (braces). A windproof layer having a certain degree of strength is formed by fixing to a structural material such as a reinforcing material such as an edge or a streak.

[0004] However, the above-mentioned conventional sheathing board does not have such strength that it can withstand the expansion force of the heat-insulating layer, but itself functions as a structural face material. Therefore,
The strength of the structural portion around the seasing board had to rely solely on the above structural members other than the easing board. In addition, the sheathing board has a disadvantage that the waterproofness is inferior.

A technique of a fiberboard comprising oil palm fibers and a binder has been disclosed (JP-A-50-156586).
However, there was a problem that strength and waterproofness were insufficient.
Structural material consisting of porous material containing coconut fiber and alkyl resorcinol-formaldehyde condensate (Patent No. 252)
No. 9168), a structural material composed of coconut fiber and a polyhydric phenol-aldehyde condensate (JP-A-8-108509), a board formed by adhering an organic fiber such as wood fiber and an aqueous dispersion of a thermosetting resin (JP-A No. 8-108509). Among the techniques relating to 7-124915), a technique of mixing a wax into a condensate of a binder is disclosed. However, the binder is not special and general, and a large amount of the binder is required to exhibit sufficient water resistance. When the wax is mixed, there is a problem that the binding of the fibers by the binder is inhibited and the strength as a structural material is reduced.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points.
The coconut fibers are securely fixed with a curable resin, and if necessary, a knitted woven fabric having a suitable tensile strength and tensile modulus (particularly a knitted woven fabric composed of vegetable natural fibers such as hemp fiber) is integrated with the resin. Another object of the present invention is to provide a fiberboard having both good moisture permeability and high strength, and further having good waterproofness by adding a wax. At the same time, the manufacturing method is also proposed.

[0007]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to solve these problems, and as a result, added wax to a fiberboard in which coconut fibers are bonded with a hardening resin, and particularly to the surface of the fiberboard. By applying, it has excellent strength and moisture permeability,
And found that a fiberboard with good waterproofness can be obtained,
The following invention has been reached. That is, the present invention provides: [1] a knitted woven fabric composed of 5 to 50 parts by weight of plant fiber based on 100 parts by weight of coconut fiber,
The present invention relates to a fiberboard obtained by adding a curable resin to these, compressing and molding a fiberboard, and adding 0.01 to 5 parts by weight of wax to 100 parts by weight of raw material fibers.

[2] A fiber board obtained by adhering a curable resin to a coconut fiber mat and compression-molding, wherein at least one surface of the fiber board has a thickness of 0.5 to 2 before or after compression molding.
The present invention relates to a fiberboard to which 00 g / m ² of wax is added. [3] The above-mentioned [2], wherein the curable resin is attached to the palm fiber mat or wax is added to the basket of the curable resin.
The invention relates to the described fiberboard.

[4] Coco fiber 100
5 to 50 parts by weight of a knitted fabric is laminated with respect to parts by weight, a curable resin is adhered to the knitted fabric, and compression molding is performed.
Or, it relates to the fiberboard according to [3]. [5] The above-mentioned [1], wherein the palm fiber is an oil palm fiber,
The present invention relates to the fiberboard according to [2], [3] or [4]. [6] A knitted fabric made of vegetable fiber has a basis weight of 100 g / m ^2.
The present invention relates to a fiberboard according to the above [1], [3], [4] or [5], which is a knitted fabric comprising hemp fibers of up to 1200 g / m ² .

[0010] [7] is the thickness of the fiberboard is 3Mm～25mm, bending strength is ^{3N / mm 2 ~50N / mm 2} ,
And a moisture permeability coefficient of 0.1 μg / (m ² · s · Pa) -10
μg / (m ² · s · Pa) and 1 of the above [1] to [6]
The invention relates to the described fiberboard. [8] The above [1] to wherein the curable resin is an amino resin
The present invention relates to the fiberboard of [7]. [9] The fiberboard according to [8], wherein the amino resin is a resin selected from one or more of a urea resin, a melamine resin, and a urea-melamine copolymer resin.

[10] The fiberboard according to [1], wherein the curable resin is a phenolic resin. [11] A fiber mat is formed from coconut fibers, and a knitted woven fabric of 5 to 50 parts by weight is laminated on the fiber mat with respect to 100 parts by weight of raw material fibers, and 0.01 to 100 parts by weight of coconut fibers are added thereto. The present invention relates to a method for producing a fiberboard, which comprises attaching a curable resin to which 5 parts by weight of wax has been added and compression-molding the resin.

[12] A fiber mat is formed from coconut fiber, and a curable resin is adhered to the fiber mat, and at least one surface of a compression-molded fiber board has a thickness of 0.5 to 200 g / g.
The present invention relates to the method for producing a fiberboard according to the above [11], wherein m ² wax is added. [13] A fiber mat is formed from coconut fibers, and a knitted woven fabric composed of 5 to 50 parts by weight of plant fibers is laminated on 100 parts by weight of coconut fibers on the fiber mat, and a curable resin is adhered thereto and compressed. The above [1] wherein 0.5 to 200 g / m ² of wax was added to at least one surface of the formed fiberboard.
1] or [12].

[14] The above [12] or [1], wherein the wax is attached to the surface of the fiberboard and then heated to 80 to 200 ° C.
3] A method for producing a fiberboard according to the above. [15] After forming a fiber mat from coconut fibers and attaching a curable resin, 0.5 to 0.5% on at least one surface of the fiber mat.
The present invention relates to a method for producing a fiberboard which is subjected to compression molding after adhering 200 g / m ² of wax.

[16] A fiber mat is formed from coconut fibers, a curable resin is adhered thereto, and a knitted woven fabric made of vegetable natural fibers with a curable resin added to the palm fiber side and a wax added to the other side is converted to coconut fibers. The invention relates to a method for producing a fiberboard which is arranged on at least one surface of a layer and compression-molded.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Coco fibers used in the present invention include coco palm, oil palm, sago palm, date palm, sardine, nipa palm, sugar palm, pea palm, palm,
Fibers such as fibrous bark, petiole base fiber and mesocarp fiber collected from palm plants such as jujube and black clog include fibers obtained by defibrating empty palm bunch of oil palm. Also, a mixture of a plurality of types of coconut fibers is included. Here, oil palm fibers are preferred.

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 depends on the fiber packing density, depending on the fiber packing density. It is formed. Therefore, the moisture permeability of the fiber mat is extremely good. In addition, the knitted fabric is excellent in moisture permeability because the stitch has air permeability.

The size of the gaps between the fibers and the density of the gaps in the fiberboard obtained are variously changed depending on the amount of resin or the degree of compression during molding when a curable resin is adhered to the fiber mat and compression-molded. be able to. Thereby, the moisture permeability of the fiberboard can be controlled. For example, by setting the gap between the fiberboards to about 1 to 100 μm, usually about 5 to 50 μm, it is possible to produce a good fiberboard that has air permeability but does not allow rain to pass.

Among the coconut fibers, oil palm fibers are preferable, but the oil palm fibers require less labor for defibration and the like than other types of coconut fibers, and can be obtained at low cost. In addition, the oil palm fiber has a fiber length of 10 to 3
Since the length of the fiber is as long as 0 cm and the degree of bending of the fiber is larger than that of the coconut fiber, the fiber is entangled with each other, and is not easily loosened when a fiber mat is formed, and the mat can be easily handled. In addition, the fiber entanglement is large, and the fiber diameter is sometimes larger than that of coconut. Therefore, the fiberboard made of the oil palm fiber has a strong nail holding force when the nail is driven.

By laminating a knitted fabric made of a vegetable fiber or a synthetic fiber having a high tensile modulus on the coconut fiber mat, the strength is further improved. Nonwoven fabric may be used instead of knitted fabric. As synthetic fibers, polyester fibers, aliphatic or aromatic polyamide fibers, aramid fibers, polyolefin fibers such as acrylic fibers, polyethylene fibers, polypropylene fibers, vinylidene fibers, polyvinyl chloride fibers, polyurethane fibers, vinylon, rayon, cupra, acetate, etc. Are exemplified.

The knitted fabric used in the present invention is preferably a knitted fabric made of a plant fiber such as hemp fiber. Here, the hemp fibers include 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 refer to fibers obtained from these hemp.

The plant fiber includes a mixture of plural kinds of plant fibers. The knitted fabric includes a cloth formed 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. As an example of the weave structure, it is preferable to select from plain weave, twill weave, satin weave, nanaco weave (including regular and irregular), 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. Also, the basis weight is 100 g / m ^{2 to} 1200.
g / m ² is preferred. In addition, 100g / m ² ~10
00 g / m ² is preferred, and most preferably 100 g / m ²
６００600 g / m ² .

The amount of the knitted fabric to be laminated on the coconut fiber mat can be selected by a combination of the basis weight and the number of laminations depending on the physical properties such as the strength required by the portion where the fiberboard is used.
The lamination position may be on the surface or inside of the coconut fiber layer, and in the case of the surface, it may be on one side or both sides. The amount of the knitted fabric to be laminated is preferably 5 to 50 parts by weight based on 100 parts by weight of the coconut fiber. Further, the amount is preferably 5 to 30 parts by weight, most preferably 10 to 25 parts by weight. For example, a density of 0.5 g / cm ³ prepared by adhering 15 parts by weight of resin to 100 parts by weight of fiber
In the case of the fiberboard of the above, if one knitted fabric of 200 g / m ² is laminated, 5
The weight is 18 parts by weight when two 300 g / m ² knitted fabrics are laminated, and 30 parts by weight when three layers are laminated.

The curable resin used in the present invention includes a thermosetting resin and a reaction curable resin (room temperature curable resin). In the compression molding, heating is also performed if necessary.
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 catalysts,
Phenol excess), resole resin (basic catalyst, formaldehyde excess), phenol-melamine copolymer resin,
There are modified phenolic resins such as phenol-melamine-urea copolymerized resin, alkylphenol modified phenolic resin, rubber modified phenolic resin, and the amino resin is urea resin (urea resin), melamine resin, urea-melamine copolymerized resin, benzoguanamine resin, And acetoguanamine resins. 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.

Further, as a sizing agent or a binder for the fiber mat, these curable resins are preferable in terms 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, and an amino resin, that is, a urea resin, a melamine resin, and a urea melamine are particularly preferable. Polymer resins and mixed resins thereof are preferred.

The curable resin of the present invention may contain, if necessary, a plasticizer, a filler, a reinforcing material, an anti-sagging agent, a coloring agent, an antioxidant, an adhesion promoter, a curing catalyst, a physical property modifier and the like. obtain. In addition, konjac, flour, starch, etc. can be added as an adhesion promoter. The amount of the curable resin to be used is 5 to 100 parts by weight, preferably 5 to 30 parts by weight, based on 100 parts by weight of the raw fibers including vegetable fibers of knitted fabric in addition to coconut fibers. More preferably, 10 to 30 parts by weight is exemplified.

In the present invention, the attachment of the curable resin means that the curable resin is present or contained, for example, when the curable resin is adhered, applied, mixed or sprayed on palm fibers, fiber mats, and / or knitted fabrics. The term "attachment" is used in a comprehensive sense. The wax used in the present invention is paraffin wax, micro stalin wax,
Includes petroleum waxes such as petrolatum, animal waxes, vegetable waxes, mineral waxes and synthetic waxes such as polyethylene waxes. These waxes are hydrophobic, and when added to a fiber board made of coconut fiber, for example, rainwater and the like are less likely to permeate into the fiber board, and the waterproofness is improved.

The wax may be added before or after the compression molding. When added before molding, the curable resin may be mixed with the curable resin, or the curable resin and wax may be separately added to the coconut fiber. When wax is attached to the surface of the fiberboard, the wax may be added to the surface before molding, compression-molded, or adhered to the surface of the compression-molded fiberboard. The wax may be adhered to only one side or both sides of the fiberboard, or may be attached to a cut surface of the fiberboard, that is, to the edge of the fiberboard. If the wax is added after attaching the curable resin to the coconut fiber, the wax can be present on the coconut fiber surface without reducing the adhesive performance of the curable resin,
preferable. It is effective and more preferable to apply wax after molding, that is, after the resin is cured, in order to enhance the effect of the wax without affecting the adhesive performance of the curable resin.

As a usage form of the wax, there is a solid wax or a wax emulsion. When a solid wax is used, there are a case where a powder is added and a case where a heated and melted one is applied by a hot melt spray gun or the like. Examples of the wax emulsion include those using a cationic, anionic or nonionic emulsifier, and those using an anionic emulsifier are preferred. In order to add the wax emulsion to the surface of the fiberboard, it may be applied by a spray gun or the like, and there is no particular limitation. The concentration of the wax emulsion is 5 to 50 wt% in terms of wax solids,
Preferably it is 15 to 45 wt%. When mixed with a curable resin, there is no particular problem with the concentration, but when added by spraying or the like, if the concentration is less than 5 wt%, a large amount of water is applied at the same time, so it is not preferable.
If the content is 0 wt% or more, the stability of the wax emulsion may be poor and the spray nozzle may be clogged.

The wax is added in an amount of 0.01 to 5 parts by weight, preferably 0.05% by weight, based on 100 parts by weight of raw fibers including vegetable fibers of knitted fabric in addition to coconut fibers.
To 3 parts by weight, more preferably 0.1 to 2 parts by weight. If the amount of wax added is less than 0.01 part by weight, the waterproof effect is small, and if it exceeds 5 parts by weight, strength and moisture permeability tend to be reduced. The amount of wax to be attached to the fiberboard surface is 0.5 to 500 g in terms of wax solids.
/ M ² , preferably 0.5 to 300 g / m ² , more preferably 0.5 to 200 g / m ² . If it is less than 0.5 g / m ² , the obtained water repellent effect is insufficient, and 500 g / m 2
It exceeds ² when the air permeability of the fiber plate, in addition to the moisture permeability decreases,
It is easy to be uneconomical.

The wax may be added before or after the hot press molding of the fiberboard.
It is preferable to further heat after wax application. By heating above the melting point of the wax, the wax melts and penetrates sufficiently into the fiberboard surface, and when an emulsion is used, the water in the emulsion volatilizes and the effect of the emulsifier disappears. The water repellency is significantly improved.

The heating temperature depends on the form and melting point of the wax, but is usually from 50 to 200 ° C., preferably from 100 to 18 ° C.
0 ° C. When an emulsion is used, a large amount of water is contained, so that the temperature is preferably from 120 to 180 ° C. If the temperature is lower than 50 ° C., the wax is not sufficiently melted. If the temperature is higher than 200 ° C., the fiberboard is burned, and the strength may be lowered. The heating time also depends on the form, melting point and heating temperature of the wax, but is usually about 10 seconds to 30 minutes at 120 to 180 ° C. If the temperature is higher than 10 seconds, the melting and permeation of the wax and the volatilization of water in the emulsion are insufficient if the temperature is lower than 30 seconds. If the temperature is lower than 30 minutes, the production efficiency is poor and the temperature lowers the strength of the fiberboard.

In the present invention, the addition of a wax refers to a case where a wax and a curable resin are mixed and used, a case where a wax is adhered or applied after a curable resin is adhered to a fiber mat, and a case where a curable resin is applied to the fiber mat. Including the case of attaching or applying wax after applying resin and compression molding,
The meaning of adding or including the wax is comprehensively used in the expression of addition, and does not limit the method of making the wax present in the fiberboard.

An embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a fiberboard 1 which is an example of the embodiment. A mat 2 is formed by coconut fibers, and a hemp cloth 3 formed by weaving yarns made of hemp fibers vertically and horizontally is arranged on both surfaces of the fiber mat 2 as a knitted fabric. In No. 3, wax is further applied (omitted) to the outer surface and compression molded.

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 a 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 m.
It is said that it is easy to use when the thickness is about m to 20 mm. However, it is needless to say that the present invention is not limited to this, and may be set arbitrarily according to the intended use.

The thickness of the fiberboard 1 of the present invention is 3 mm to 25 mm.
mm is preferable, and 9-20 mm is more preferable. The fiberboard 1 has high strength and is adjusted to the density of the fiberboard 1 and the amount of the curable resin so that, for example, the bending strength and the wet bending strength are equal to or higher than that of a medium fiberboard of 5 to 30 types. On the other hand, it is also possible to obtain a value whose moisture permeability is equal to or higher than that of the seasing board.

The flexural strength of fiber board is preferably 3~50N / mm ^2, more preferably 5~40N / mm ^2, 10~
40 N / mm ² is most preferred. If it is less than 3 N / mm ² , the strength of the structural material is insufficient, and if it is more than 50 N / mm ² , it is generally necessary to increase the fiberboard density, which leads to a decrease in moisture permeability, making it possible to achieve both strength and moisture permeability. Disappears.
Moisture permeation coefficient ^{0.1~10μg / (m 2 · s ·} Pa) is ^{preferable, 0.5~8μg / (m 2 · s} · Pa) , more ^{preferably, 1~7μg / (m 2 · s} · Pa ) Is most preferred. If it is less than 0.1 μg / (m ² · s · Pa), it is insufficient as a windproof layer for transmitting water vapor to the ventilation layer in the wall,
In order to make it 10 μg / (m ² · s · Pa) or more, it is generally necessary to lower the density of the fiberboard, so that the strength is reduced and it becomes impossible to achieve both strength and moisture permeability.

Further, the density of the fiberboard is 0.2 g / cm ³ or more.
1 g / cm ³ is preferable, and further 0.3 g / cm ^{3 to} 7 g
/ Cm ³ , most preferably 0.35 g / c
m ^{3 to} 0.6 g / cm ³ . In addition, the basis weight of the fiberboard 1 is, for example, when the thickness of the fiberboard 1 is 9 mm, the density is 0.1%.
At 2 g / cm ³ , the basis weight is 1.8 kg / m ² and the density is 1 g.
/ Cm ³ , the basis weight is 9 kg / m ² .

The method for producing the fiberboard 1 can be carried out, for example, as follows. First, coconut fibers are defibrated to obtain fibers having a unit sectional diameter of about 5 to 600 mm and a fiber length of 30 to 300 mm. A fiber mat 2 is formed from the coconut fibers, and the fibers are entangled by a needle punch or the like to make the fibers dense, and at the same time, the peel strength is increased. An aqueous solution or aqueous dispersion of a curable resin is sprayed on the fiber mat 2 by spraying or the like, so that the resin is uniformly attached to the entire fiber mat. In the case where the knitted fabric is laminated on both surfaces of the fiber mat, a resin liquid is applied to one side of the hemp cloth 3 and a wax 4 is applied to the other side by spraying, and the surface on which the resin is adhered is placed on the fiber mat side. The hemp cloth 3 is arranged on both sides of the fiber mat 2 and is subjected to heat compression molding. Depending on the density and thickness of the desired fiberboard, a plurality of fiber mats may be appropriately laminated.

Since the temperature and time of the heat compression vary depending on the used cured resin and the water content of the fiber mat before the heat compression, the temperature and the time may be appropriately adjusted according to the respective conditions. When the hemp cloth 3 is not used, after applying the resin to the fiber mat 2,
Wax 3 is applied to the outer surface of the fiber mat to be laminated, and is molded by heating and pressing. The wax 4 can be applied after forming the fiberboard, or can be added to the curable resin in advance. When applying wax after molding, the wax is applied to the surface of the molded fiberboard with a spray gun and then heated. Heating can be performed by a heating furnace, a hot press, or the like. When a solid wax is used, hot melt spray is used, and when applied in a heating furnace, wax application and heating after application can be performed simultaneously.

The resin is used as a sizing agent or binder for the fiber mat 2, imparts strength to the hemp cloth itself and a binder between the hemp cloth 3 and the fiber mat 2, and further a binder for the entire fiber board. Alternatively, it works as a component for imparting strength. In addition, the hemp cloth 3 is knitted with hemp fiber or the like having a moderately high tensile strength and tensile elastic modulus, and therefore exhibits excellent tensile strength and tensile elastic modulus itself. Then, the hemp cloth 3 is strongly bonded to the fiber mat 2 via the resin, thereby increasing the strength of the fiberboard. That is, when the hemp cloth 3 is arranged on both sides of the fiber mat 2, a so-called sandwich effect is exerted, and the bending strength and the bending elastic modulus of the fiber board are increased. Furthermore, hemp cloth 3 absorbs water,
Since the dimensional change at the time of moisture absorption is small, it is preferable to arrange the fiber mat 2 on both sides, particularly, since the water absorption of the fiber board, the dimensional change at the time of moisture absorption, and the decrease of the strength at the time of water absorption and moisture absorption are small. Therefore,
The fiberboard 1 functions as a structural face material, and can reinforce the structural portion around the windbreak layer.

In the above, the hemp cloth 3 is replaced with the fiber mat 2
However, in the present invention, when the hemp cloth 3 is not laminated on the surface of the fiber mat 2, the hemp cloth 3 is further disposed only on one surface, the hemp cloth 3 is disposed inside the fiber mat 2, Surface or one surface as well as those disposed inside. Further, when the hemp cloth is arranged inside the fiber mat 2, a case where a plurality of hemp cloths and a plurality of palm fiber mats 2 are alternately stacked and arranged in a multilayer shape is included. When the hemp cloth is placed inside the fiber mat 2, the tensile strength and the tensile modulus, the shear strength and the shear modulus, and the in-plane compressive strength and the in-plane compressive modulus of the fiberboard are increased. It functions as a structural surface material and can reinforce the structural part around the windbreak layer.

Next, one example of a method for producing the fiberboard 1 is shown in FIG.
First, a fiber mat 2 is formed from coconut fibers. The mechanism used in this process is, for example, as shown in FIG. 2, a plurality of hoppers 5 provided in series in the belt traveling direction on the information of the belt conveyor 4, a needle punch device 6 is provided downstream of the hopper 5, and a belt conveyor downstream thereof is provided. The spray guns 7, 7 are provided above and below the spray gun 4, respectively. Coconut fiber is put into the hopper 5, and curable resin and wax are supplied to the spray gun 7 under pressure. 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 coconut fibers are entangled by the needle punch device 6, and further the coconut fibers are directed from the spray gun 7 toward the coconut fibers. The fiber mat 2 is formed by jetting and supplying a curable resin and a wax. Next, the fiberboard 1 is formed by hot compression molding using a hot press or the like. Heat compression molding includes a continuous molding method using a thermocompression roller or a belt press, and a batch molding method using a single-stage or multi-stage press.

In this figure, the curable resin and wax are attached to the fibers by spraying with a spray gun 7, but the fibers may be attached by immersing the fibers in a mixture of the curable resin and wax. The wax may be added by spraying or the like after the curable resin is adhered to the fiber mat 2 and subjected to heat compression molding. Further, in the above embodiments, only the fiberboard having a rectangular shape in a front view and a constant thickness has been described.However, it may be a molded body formed into a desired shape by various shapes of molds at the time of compression hardening molding. The same operation and effect as those of the fiberboard can be obtained.

The fiberboard 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, architectural structural material heat insulating materials, sound absorbing materials, sound insulating materials, shock absorbing materials, cushioning materials, rims, etc. It can be used for all building material applications where plywood, glulam, particle board, etc. are used as building materials. Furthermore, it can also be used as a material for concrete forms, pallets, packaging materials, vehicle interior materials such as automobiles, interior base materials, exterior materials, furniture materials and the like.

[0045]

Next, the present invention will be described in detail with reference to examples and comparative examples. Without laminating a knitted fabric, 10 parts by weight of urea resin and 1 part by weight of wax were attached to 100 parts by weight of coconut fiber in the same procedure as in Example 1 below, and the conditions were set at 165 ° C. for 15 minutes. The fiber plate having a density of 0.5 g / cm ³ formed by heating and compression molding has a bending strength of 16.8 N / mm ^{2. According} to the method for evaluating waterproofness shown in Example 1 below, the time required for water droplets dripping on the surface to permeate is 42 minutes. there were.

Since the present invention relates to both a fiber board having no knitted fabric and a fiber board having a knitted fabric laminated on the surface of the fiber board, examples of a palm fiber board having a knitted fabric laminated are shown below as typical examples. . Using Example 1 fibrillating the oil palm fibers, the fibers are entangled by needle punching to prepare a fiber mat having a basis weight of 1.7 kg / m ^2. Urea resin (Mitsui Toatsu Chemical's Euroid U-755, resin solid content 65wt%) and wax emulsion (Nippon Seiwa Co., Ltd., paraffin wax EMUSTAR)
-0135, solid content 40 wt%), and NH ₄ C as a curing catalyst
l (1 part by weight based on 100 parts by weight of resin solids)
Diluted with water, resin solid content 40wt%, wax solid content 2.7wt%
Was prepared. The resin solution was spray-coated on the above-mentioned oil palm mat and a jute cloth having a basis weight of 0.3 g / m ² by a spray method, and a resin solid content of 15 wt.
Parts by weight of urea resin and 1 part by weight of wax were deposited. Two oil palm fiber mats with resin adhered thereto, one jute cloth on each side (18 parts by weight with respect to 100 parts by weight of coconut fiber), were laminated, and then pressed at 165 ° C.-10
Minutes, heat compression molding, thickness 9.0 mm, density 0.5 g /
A cm ³ fiberboard was obtained.

The obtained fiberboard was evaluated according to the following evaluation items and methods. The bending strength was measured by a measuring method of JIS A 5905 fiberboard. The moisture permeability was measured according to the method for testing the moisture permeability of JIS Z 0208 moisture-proof packaging materials. For waterproofness,
One drop of water (approx. 50 mg) on the fiberboard surface at 10 locations with a pipette
The time at which the water droplets permeated the fiberboard and disappeared was measured, and the time at which the third to eighth droplets disappeared was evaluated as the water droplet retention time. The results of these evaluations are shown in Table 1. Example 2 The procedure of Example 1 was repeated, except that the wax concentration in the urea resin solution of Example 1 was increased, and 3 parts by weight of wax was attached to 100 parts by weight of the fiber.
m, a fiberboard having a density of 0.5 g / cm ³ and 3 parts of wax added. The obtained fiberboard was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1. Example 3 Urea resin, water and NH ₄ Cl as a curing catalyst
(1 part by weight based on 100 parts by weight of resin solid content)
A urea resin solution having a resin solid content of 40 wt% was prepared. The urea resin solution was applied to an oil palm mat having a basis weight of 1.7 kg / m ² and a jute cloth having a basis weight of 0.3 g / m ² , and 15 parts by weight of resin in terms of resin solid content was adhered to 100 parts by weight of coconut fiber.
Two oil palm fiber mats with resin attached, one jute cloth on each side, and heat compression molding at 165 ° C for 10 minutes to produce fibers with a thickness of 9.0 mm and a density of 0.5 g / cm ³ I got a board. Wax emulsion on both surfaces of this fiberboard (Mobile Oil Mobile C, solid content 44wt%)
At a solid content of 50 g / m ² (3 parts per 100 parts by weight of raw fiber)
(Equivalent to parts by weight), and dried at room temperature (20 ° C.) to obtain a fiberboard having wax attached to both surfaces. The resulting fiberboard is
Evaluation was performed in the same manner as in Example 1, and the evaluation results are shown in Table 1. [Example 4] A thickness of 9.0 m produced in the same manner as in Example 3.
50 g / m ² solid content of wax emulsion (Mobil Oil Mobilcer C) on the surface of a fiberboard having a density of 0.5 g / cm ³ and a density of 0.5 g / cm ^3.
After the application, the coating was heated at 165 ° C. for 2 minutes to obtain a fiberboard having wax adhered to both surfaces. The obtained fiberboard was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1. Example 5 As in Example 3, an urea resin solution was applied to an oil palm mat and a jute cloth. After the resin was applied to the jute cloth, a wax emulsion was further applied to one surface of the jute cloth at a solid content of 50 g / m ² . Two palm fiber mats with resin attached, one jute cloth on each side of the mat, with the wax-coated side facing out, were laminated by heating and compression molding at 165 ° C for 10 minutes to a thickness of 9.0 mm and a density of 9.0 mm. 0.5 g / cm
³ and a fiberboard having wax attached to both surfaces was obtained. The obtained fiberboard was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1. [Example 6] In the same manner as in Example 5, a urea resin solution was applied to an oil palm mat and a jute cloth, and after the resin was applied to the jute cloth, solid wax (Nippon Seiwa wax 135) was applied to one surface of the resin. The powder was deposited at 50 g / m ² . These palm fiber mats and jute cloths were laminated and heated and compression-molded in the same manner as in Example 5 to a thickness of 9.0 m.
m, a fiberboard having a density of 0.5 g / cm ³ and wax attached to both surfaces was obtained. The obtained fiberboard was evaluated in the same manner as in Example 1, and the evaluation results are shown in Table 1. [Comparative Example 1] As in Example 3, the thickness was 9.0 mm and the density was 0.5 g /
A cm ³ fiberboard without wax was obtained. The obtained fiberboard was evaluated in the same manner as in Example 1 without applying wax, and the evaluation results are shown in Table 1.

As shown in Table 1, from the comparison between Example and Comparative Example 1, it was found that the addition of the wax or the application to the surface significantly improved the water droplet holding time. In Example 2 and Examples 3 to 6, wax was added or applied (adhered).
The amount was the same at 3 parts by weight, and the water drop retention time was almost at the same level. However, when wax was added to the resin as in Example 2, the bending strength tended to decrease. When wax was applied to the coconut fiber board surface as in Examples 3 to 6, the water drop holding time could be significantly improved without lowering the bending strength and the moisture permeability coefficient. Further, from the comparison of Examples 3 and 4, the wax is melted by applying the wax emulsion and then heated, so that the wax can be sufficiently penetrated into the fiber, the dispersion of the water droplet holding time is eliminated, and the holding time is greatly improved. We were able to.

[0049]

[Table 1]

[0050]

As described above, a fiberboard is obtained by laminating a vegetable fiber knitted fabric on a palm fiber mat as required, adhering a curable resin thereto, and compression-molding the fiberboard. By adding or applying to the surface, a fiberboard excellent in strength and moisture permeability and excellent in waterproofness could be provided. When wax was applied to the surface of the coconut fiber board without being mixed with the curable resin, high waterproofness was able to be exhibited without reducing strength. In addition, by heating after attaching the wax to the surface of the fiberboard, stable and good waterproofness could be exhibited.

Further, a manufacturing method suitable for the above fiberboard could be proposed. Since the fiberboard of the present invention is excellent in strength and moisture permeability and has good waterproofness, if a windproof layer is formed with these fiberboards, indoor water vapor can be smoothly transmitted through the ventilation layer, In addition to being able to stably hold the heat insulating layer, since it is excellent in waterproofness, intrusion of water from the outside can be prevented.

The use of the fiberboard of the present invention is not limited to a windproof layer, but is excellent in strength, moisture permeability and waterproofness.
Tatami materials, roof base materials, ceiling materials, home interior materials, interior base materials,
Also used as architectural heat insulating material, rim material, sound insulation material, sound absorbing material, cushioning material, shock absorbing material, concrete formwork material, loading pallets, vehicle interior materials such as automobiles, base material for vehicle interiors such as automobiles, furniture materials, etc. You can do it.

Further, by using oil palm fiber for the palm fiber, in addition to the above-mentioned effects, energy required for production can be reduced, and thus cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a fiberboard in which a knitted fabric is laminated on both surfaces, which is one of the embodiments.

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 the knitted fabric of the embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber board 2 Fiber mat 3 Hemp cloth (knitted fabric) 4 Belt conveyor 5 Hopper 6 Needle punch device 7 Spray gun

Claims (16)

[Claims] A fibrous board obtained by laminating a knitted fabric in an amount of 5 to 50 parts by weight with respect to 100 parts by weight of a coconut fiber on a coconut fiber mat, adhering a curable resin thereto, and compressing and molding the woven fabric. A fiberboard obtained by adding 0.01 to 5 parts by weight of wax to 100 parts by weight. 2. A fiberboard formed by adhering a curable resin to a coconut fiber mat and compression molding, wherein at least one surface of the fiberboard before or after compression molding has a thickness of 0.5 to 20%.
Fiberboard to which 0 g / m ² of wax is added. 3. The fiberboard according to claim 2, wherein a wax is added after the curable resin is attached to the coconut fiber mat or after the curable resin is cured. 4. A knitted fabric consisting of 5 to 50 parts by weight of plant fiber with respect to 100 parts by weight of coconut fiber is laminated on a coconut fiber mat, and a curable resin is adhered to these, followed by compression molding. Or the fiberboard according to 3. 5. The fiberboard according to claim 1, wherein the palm fiber is an oil palm fiber. 6. A knitted woven fabric composed of vegetable fibers has a basis weight of 100 g.
/ M ² ~1200g / m is a knitted fabric comprising ^two hemp fibers according to claim 1, 3, 4 or 5 fiberboard according. 7. A fiberboard having 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 /
(M ² · s · Pa) fiberboard one of claims 1 to 6 is. 8. The method according to claim 1, wherein the curable resin is an amino resin.
7. The fiberboard according to 7-1. 9. An amino resin comprising a urea resin, a melamine resin,
The fiberboard according to claim 8, which is a resin selected from one or more of urea-melamine copolymer resins. 10. The fiberboard according to claim 1, wherein the curable resin is a phenol resin. 11. A fiber mat is formed from coconut fiber, and a knitted woven fabric is laminated on the fiber mat in an amount of 5 to 50 parts by weight based on 100 parts by weight of coconut fiber. A method of producing a fiberboard, comprising: adhering a curable resin to which 01 to 5 parts by weight of a wax has been added, followed by compression molding. 12. A fiber mat is formed from coconut fibers.
Compression molded fiber with curable resin attached to fiber mat
0.5 to 200 g / m on at least one surface of the plate ^TwoNo
The method for producing a fiberboard according to claim 11, further comprising adding a fiber. 13. A fiber mat is formed from coconut fibers, and a knitted fabric comprising 5 to 50 parts by weight of plant fibers is laminated on 100 parts by weight of coconut fibers on the fiber mat, and a curable resin is adhered thereto. Compression molded fiberboard
Preparation of fiberboard according to claim 11 or 12, wherein the addition of wax 0.5 to 200 g / m ² to the surface. 14. After the wax is added to the surface of the fiberboard, 8
The method for producing a fiberboard according to claim 12 or 13, wherein the fiberboard is heated to 0 to 200 ° C. 15. A fiber mat formed from coconut fibers, a curable resin is adhered, a wax of 0.5 to 200 g / m ² is added to at least one surface of the fiber mat, and then a compression-molded fiber board is formed. Manufacturing method. 16. A knitted woven fabric composed of vegetable natural fibers having a curable resin adhered to a palm fiber side and a curable resin added to the other side, and a wax added to the other side to form a fiber mat from palm fibers. A method for producing a fiberboard, which is disposed on at least one surface of the fiberboard and compression molded.