JP2965394B2 - Method for producing fiber molded article and suction mold - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a fiber molded product having a partially different thickness and a suction mold used for the method.

[0002]

2. Description of the Related Art Various fiber molded products are used in automobiles, chemical devices, water heaters, heaters and the like. These fiber molded products are used as cushioning materials, sealing materials, heat insulating materials, and the like. The fibers may be synthetic resin fibers such as polyamide and polyester fibers,
Examples include natural fibers such as cellulose pulp and hemp, and inorganic fibers such as ceramic fiber and glass fiber. In order to manufacture the above-mentioned fiber molded product, as shown in FIG. 13, the fiber 80 is suspended in a liquid (water) to form a slurry 901, which is then transferred to a suction mold 9 having a porous mold surface 92. The slurry is fed into the inside using a slurry pump 902. In the suction mold 9, the slurry 90 is supplied from a decompression chamber 93 provided behind the porous mold surface 92.
Aspirate the liquid in 1.

[0003] As a result, the fibers 80 are sucked and deposited on the porous mold surface 92, and the outer shape is changed to the porous mold surface 9.
Thus, a fiber molded product (see FIG. 12 described later) along the inner wall surface is obtained. At the time of the above suction, the suction pump 9
7 is operated, and the pressure in the decompression chamber 93 is reduced through the pipe 96 and the suction box 94 of the suction mold 9. Then, the liquid in the slurry is discharged by the suction pump 97.

[0004] The decompression chamber 93 is provided with a porous mold surface 92.
And the outer cylinder 91. Further, as the porous mold surface 92, a porous plate having a large number of pores (3 to 15 mm in diameter) or a porous material capable of separating the fiber and the liquid, such as a fine metal mesh, is used. Further, in the above manufacturing method, a fiber molded article having a bottomed cylindrical shape is obtained. By the way, many fiber molded products have substantially the same thickness at the side wall and the bottom. For example, the bottom is required to have a larger thickness than the side wall. That is, a fiber molded product having a partially different thickness is required (see FIG. 12).

Conventionally, when manufacturing fiber molded products having different thicknesses as described above, as shown in FIG.
A step method is used. That is, first, as shown in FIG. 13, the slurry 901 is put into the suction mold 9, and as shown in FIG. 12 (A), the entire thickness is substantially the same, and the intermediate thickness is about half of the final thickness. A fiber molded product 81 is made. Therefore, once supply of slurry was stopped,
As shown in FIG. 12 (B), a thickness adjusting plate 85 is placed on the bottom of the intermediate fiber molded product 81 in the suction mold where the thickness is to be increased. Thereafter, the slurry is again charged into the suction mold, and suction molding is performed. As a result, as shown in FIG. 12C, a final fiber molded product 83 having the bottom 832 having a large thickness and the side wall 831 having the final thickness is obtained.

[0006]

However, the above-mentioned conventional method requires the thickness adjusting plate 85 and the steps of producing the intermediate fiber molded article 81, placing the thickness adjusting plate 85, and subsequently performing the final suction molding. It is. Therefore, productivity is low. Further, since the thickness adjusting plate 85 placed in the fiber molded product is different from the fiber constituting the main body, the portion may be deformed during use of the fiber molded product. SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned conventional problems, and has as its object to provide a method of manufacturing a fiber molded product which is easy to mold and has excellent productivity, and has a partially different thickness, and a suction mold for the same.

[0007]

According to the present invention, a slurry is prepared by suspending fibers in a liquid, the slurry is introduced into a suction mold having a porous mold surface, and the liquid in the slurry is dispersed in the porous mold surface. Suction into the decompression chamber provided behind, and forming a fiber molded product on the porous mold surface,
The suction mold includes a plurality of porous mold surfaces, a decompression chamber corresponding to each of the porous mold surfaces, a suction box for connecting to a suction pump, and a suction box and the decompression chamber. It has a separator provided in between, and a suction port provided in the separator, and a stopper for adjusting suction pressure is detachably arranged in the suction port, so that the suction pressure of the decompression chamber is made different. The method for producing a fiber molded product is characterized in that the slurry is sucked in the state and a fiber molded product having a partially different thickness is obtained. The most remarkable point of the present invention is a suction device having a plurality of partitioned porous surfaces and a decompression chamber, and a detachable stopper for adjusting a suction pressure provided at a suction port of the separator in each decompression chamber. The purpose of the present invention is to perform suction of the slurry by using a mold and changing the suction pressure of the decompression chamber.

[0008] Each of the porous mold surfaces, behind,
It has a corresponding decompression chamber. The number of the porous mold surfaces is arbitrary, but at least the number of different thicknesses is necessary. For example, when the bottom and the side wall of the fiber molded product have different thicknesses, a porous mold surface divided into the bottom and the side wall and a decompression chamber are required (see Examples). In this case, for example, the porous mold surface for forming the side wall and the decompression chamber are all set to the same suction pressure, and the porous mold surface for the bottom portion and the decompression chamber are set to another suction pressure (see FIG. 1). When it is desired to further increase the thickness of the side wall to two types, the porous mold surface for the side wall is divided into two sets and the bottom part is also divided, thereby forming three sets of the porous mold surface and a decompression chamber.

Further, as shown in the embodiment, in order to facilitate removal of the fiber molded product, when the suction mold is a split mold, the porous mold surface and the decompression chamber are, for example, 5 mm.
It can also be divided into sections (see FIGS. 7 and 8). Next, a plate-shaped separator is interposed between each decompression chamber and the suction box. The separator is provided with a suction port. The suction port is provided with a detachable stopper for adjusting the suction pressure in each decompression chamber. That is, when the suction pressure of the decompression chamber is to be increased (the degree of decompression is large), the stopper is removed, and when the suction pressure is to be reduced, the stopper is fitted.

In the present invention, the suction pressure of the decompression chamber is adjusted by attaching and detaching a stopper. Therefore, usually, a plurality of suction ports are provided in each separator. For example, one separator is provided with three suction ports, and one or two of them are closed with a stopper. Also, depending on the structure of the fiber molded product to be obtained,
It may not be necessary to deposit fibers on one porous mold surface. In this case, all of the suction ports of the separator of the decompression chamber corresponding to the porous mold surface are closed with a stopper.

As is known from the above, the number of suction ports in each separator is usually plural, but may be only one. Further, since the adjustment of the suction pressure of each decompression chamber is relative, any one of the separators may be provided with only one suction port as a reference suction port. In the above sense, it is preferable that at least one of the separators provided in each decompression chamber has a plurality of suction ports. The adjustment of the suction pressure is performed by changing the total opening area of the suction ports in each separator. Examples of the material of the stopper include rubber, plastic, and wood. In addition, as a stopper, a plug that is simply inserted or inserted into the suction port,
There is a screw-in type.

[0012] As a suction mold for carrying out the above-mentioned manufacturing method, there are a plurality of porous mold surfaces, a decompression chamber provided behind each porous mold surface, and a suction pump for connecting to a suction pump. A box, a separator disposed between the suction box and each of the decompression chambers, a suction port provided in the separator for communicating the two, and a suction pressure adjusting closure detachably disposed in the suction port. A suction mold having a stopper, wherein a suction pressure in each of the decompression chambers is varied by changing a state of attachment / detachment of the stopper to the suction port. There is a suction mold.

[0013]

According to the production method of the present invention, the suction molding has a porous mold surface divided into a plurality of sections and a decompression chamber, and a suction port provided in a separator of each decompression chamber is provided with a detachable stopper plug. Using a mold, the suction pressure of the decompression chamber is varied to suction the slurry. Prior to the suction of the slurry, the stopper is attached to or removed from the suction port, and the suction pressure of each decompression chamber is adjusted so as to be different during the suction of the slurry. Therefore, a large amount of fibers accumulate on the surface of the porous mold surface where the suction pressure is large, and a small amount of fibers accumulate on the surface of the porous mold surface where the suction pressure is small. Therefore, a fiber molded product having a partially different thickness can be obtained.

The adjustment of the suction pressure can be arbitrarily performed by attaching or removing a stopper. Therefore, 1
With one suction mold, fiber molded products of various thicknesses can be arbitrarily and easily manufactured. Further, in the present invention, since the thickness adjusting plate is not used unlike the conventional method, the steps of suction molding of the intermediate fiber molded product, arrangement of the thickness adjusting plate, and final suction molding are not required. Therefore, it is easy to manufacture and excellent in productivity.

Further, since the thickness adjusting plate is not provided inside the fiber molded product, the whole is homogeneous and there is no possibility of distortion. Further, in the above suction mold, the opening area of the suction port is made different by attaching and detaching the stopper, so that the suction pressure can be adjusted and the device is simple. As described above, according to the present invention, molding is easy and excellent in productivity.
It is possible to provide a method for producing a fiber molded product having a partially different thickness. Further, it is possible to provide a suction mold exhibiting such an effect.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for producing a fiber molded product and a suction mold according to an embodiment of the present invention will be described with reference to FIGS. First, as shown in FIG. 9 and FIG.
And a square shaped side wall 72. And
The bottom 73 has a thickness that is about three times that of the side wall 72.
Further, one opening hole 71 is provided in the side wall. The fiber molded product 7 is a heat insulating case arranged to cover the outer periphery of the gas water heater. The opening 71 is an insertion portion of a burner to be inserted into the gas water heater.

Next, a suction mold 1 for suction-molding the fiber molded article 7 will be described with reference to FIGS. First, as shown in FIGS. 1 to 8, the suction mold 1 has a plurality of divided porous mold surfaces 121 to 124 and 13.
And decompression chambers 151 to 15 provided behind the porous mold surface.
4, 130 (FIGS. 7 and 8) and a suction box 16 for connection to a suction pump 97. Further, plate-like separators 20 to 24 (FIG. 3) provided between the suction box 16 and the decompression chambers 151 to 154 and 130 are provided with suction ports 20 for communicating the decompression chambers and the suction box 16.
0, 211, 211, 211, and 241 (see FIGS.
(Fig. 6).

That is, as shown in FIG. 3, in the decompression chamber 130 for forming the bottom of the fiber molded product,
Two suction ports 200 are provided in the separator 20.
In the decompression chambers 151 to 154 for forming the side walls, three suction ports 211, 221, 21 and 241 are provided in the separators 21 to 24, respectively. In addition, the suction ports 200, 211, 221, 231, 24
1 includes a rubber stopper plug 30 to 3 which is detachably mounted.
4 (FIGS. 3 to 6).

The porous mold surfaces 121 to 124 and the decompression chambers 151 to 154 are used for forming the side wall 72 of the fiber molded product 7, and the porous mold surface 13 and the decompression chamber 130 are used for forming the bottom 73 of the fiber molded product 7. This part is used for molding.
Further, the decompression chamber 130 is formed by the porous mold surface 13, the separator 20, and the partition wall 131 provided in an elliptical cylindrical shape between the both surfaces (FIG. 2). As will be described later, the suction mold 1 is a split mold that opens in four directions (FIG. 7, FIG.
(FIG. 8).

As shown in FIGS. 7 and 8, each of the decompression chambers 151 to 154 has a porous mold surface 121 to 124 and an outer cylinder 1.
1 is formed. Then, the porous mold surface 122
In the lower part of the opening, an opening 71 of the fiber molded product 7 (FIG. 9)
A blind plate 18 is provided to make the fiber, that is, to prevent the fibers from being adsorbed. In addition, each porous mold surface 12
The lower end of each of 1 to 124 has a non-porous wall 134. The outer cylinder 11 is composed of outer cylinder plates 111 to 114. That is, the porous mold surfaces 121 to 124, the decompression chambers 151 to 154, and the outer cylinder plates 111 to 114 each constitute one set, and can be opened in four directions as shown in FIGS. . Each of these sets is connected to the hinge 13 near the separator 20 to 24.
6 (FIGS. 1 and 2). An airtight sealing material is provided between the separators 20 to 24 (not shown).

Next, in the suction molding, first, the suction ports of the separators 20 to 24 are closed so that each of the decompression chambers has a suction pressure corresponding to the thickness of the fiber molded product to be obtained. Closed by ~ 34. In this example, in FIG.
Always open. And other separators 21 and 2
Each of the three suction ports in 4 is closed by a closing plug 31 to 34 one by one. Thereafter, the slurry is supplied to the interior 10 of the suction mold 1 and the suction pump 97 is operated as in the conventional case. And each decompression chamber 1
The pressure in the vacuum chambers 51 to 154 and 130 is reduced, and the liquid in the slurry is separated by suction (in the direction of the arrows in FIGS. 1 and 2).

As a result, the fibers are suction-deposited on the surfaces of the porous mold surfaces 121 to 124 and 13, and the fiber molded product 7 is formed. Since the blind plate 18 has no suction force, an opening hole 71 of the fiber molded product 7 is formed in this portion. What is important here is that, as described above, the decompression chamber 15
The total opening area of each suction port provided between 1 to 154 and the suction box 16 is smaller than the opening area of the suction port 200 between the pressure reducing chamber 130 for forming the bottom and the suction box 16.

Therefore, the suction pressure in the decompression chamber 130 is
It becomes higher than the suction pressure of the decompression chambers 151 to 154. Therefore, the porous mold surfaces 121 to 12
4 more fibers are suction deposited. Therefore, as shown in FIGS. 9 and 10, it is possible to obtain the fiber molded product 7 in which the bottom portion 73 is thicker than the side wall 72. In this example, a water slurry containing ceramic fibers having a diameter of 2.5 μm and a length of 25 mm was used as the fibers. At the time of suction molding, the suction pressure of the decompression chambers 151 to 154 is about 400 to 50.
0 mmHg, suction pressure of the decompression chamber 130 is about 550 to 65
It was 0 mmHg. The fiber molded product 7 had a side wall thickness of about 10 mm and a bottom thickness of about 17 mm.

In this embodiment, the suction mold 1 is used.
As shown in FIG. 11, it is also possible to obtain a fiber molded product 7 in which the thickness of the side wall 720 on the side orthogonal to the one side wall 72 is large. In this case, all three suction ports 221 and 241 of the separators 22 and 24 are opened to adjust the suction pressure. On the other hand, the suction ports 211 and 231 on the separators 21 and 23 side are closed by closing plugs 31 and 33 except for one.
As described above, according to the present embodiment, it is possible to provide a method of manufacturing a fiber molded product which is easy to mold and has excellent productivity, and has a partially different thickness, and a suction mold.

[Brief description of the drawings]

FIG. 1 is an explanatory view of a suction mold in an embodiment.

FIG. 2 is a lower sectional view of the suction mold of the embodiment.

FIG. 3 is a sectional view taken along line AA of FIG. 2;

FIG. 4 is a sectional view taken along line CC of FIG. 3;

FIG. 5 is a sectional view taken along line DD in FIG. 3;

FIG. 6 is a sectional view taken along line EE of FIG. 3;

FIG. 7 is a sectional view taken along line BB of FIG. 2;

FIG. 8 is a plan view showing a state where the suction mold of the embodiment is opened.

FIG. 9 is a perspective view of a fiber molded product obtained in an example.

FIG. 10 is a sectional perspective view of the fiber molded product of FIG. 9;

FIG. 11 is a perspective view of another fiber molded product shown in the embodiment.

FIG. 12 is a manufacturing process diagram of a conventional fiber molded product.

FIG. 13 is an explanatory view of a method of manufacturing a fiber molded product in a conventional example.

[Explanation of symbols]

1. . . Suction mold, 11, 111-114. . . Outer cylinder, 121-124. . . 12. porous mold surface for forming side walls; . . 130. porous mold surface for bottom molding . . Decompression chamber for bottom molding, 151-154. . . 15. decompression chamber for forming side walls; . . Suction box, 20-24. . . Separator, 200, 211, 221, 231, 241. . . Suction port, 30, 31, 32, 33, 34. . . Stopper,

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-57-71500 (JP, A) JP-B-54-19256 (JP, B2) (58) Fields investigated (Int. Cl. ⁶ , DB name) D21J 7/00

Claims (3)

(57) [Claims] A slurry is prepared by suspending fibers in a liquid, and the slurry is introduced into a suction mold having a porous mold surface, and the liquid in the slurry is provided behind the porous mold surface. A method of forming a fiber molded product on a porous mold surface by sucking into a decompression chamber, wherein the suction mold comprises a plurality of partitioned porous mold surfaces and a decompression chamber corresponding to each porous mold surface. , A suction box for connecting to a suction pump, a separator provided between the suction box and each of the above-mentioned decompression chambers, and a suction port provided in the separator for communicating the two. Is characterized in that a stopper for adjusting the suction pressure is detachably arranged, and the slurry is sucked in a state where the suction pressure of the decompression chamber is varied to obtain a fiber molded product having a partially different thickness. Fiber Method for producing a molded article. 2. A plurality of porous mold surfaces, a decompression chamber provided behind each of the porous mold surfaces, a suction box for connecting to a suction pump, the suction box and each of the decompression chambers. And a suction port provided in the separator to communicate the two, and a stopper for suction pressure adjustment removably disposed in the suction port, the suction molding die comprising: A suction mold for producing a fiber molded product, characterized in that suction pressure in each decompression chamber is made different by changing a state of attachment / detachment of a closure plug to a suction port. 3. The suction mold according to claim 2, wherein at least one of the separators provided in each of the decompression chambers has a plurality of suction ports.