METHOD OF MANUFACTURING A FLAME-RETARDANT HEAT INSULATING FORMED PRODUCT

Abstract

A method of manufacturing a flame-retardant heat insulating formed product in the shape of a mat includes pouring water in used paper or a pulp material to defibrate and obtain defibrated cotton. A flame retardant such as a boric acid is charged into the defibrated cotton. By stirring and heating, a flame-retardant heat insulating defibrated cotton is obtained. Short fibers with a low melting point made of polyester or the like are charged into the flame-retardant heat insulating defibrated cotton. By mixing and stirring, a flame-retardant heat insulating loose material is obtained. A forming die made of corrugated cardboard provided with a lid having air vents is filled with the flame-retardant heat insulating loose material. The flame-retardant heat insulating loose material together with the forming die are heated with a microwave heating apparatus to form. A mat-shaped formed product is removed from the forming die.

Claims

1. A method of manufacturing a flame-retardant heat insulating formed product, including: pouring water in used paper or a pulp material to defibrate and obtain defibrated cotton; charging a flame retardant into the defibrated cotton, and by stirring and heating, obtaining flame-retardant heat insulating defibrated cotton; charging short fibers with a low melting point into the flame-retardant heat insulating defibrated cotton, and by mixing and stirring, obtaining a flame-retardant heat insulating loose material; filling a forming die made of paper provided with a lid with the flame-retardant heat insulating loose material; heating the flame-retardant heat insulating loose material together with the forming die with a microwave heating apparatus to form; and removing a formed product from the forming die.

2. The method of manufacturing a flame-retardant heat insulating formed product according to claim 1, wherein the forming die made of paper is a forming die made of corrugated cardboard.

3. The method of manufacturing a flame-retardant heat insulating formed product according to claim 1, wherein the lid of the forming die has an air vent.

4. The method of manufacturing a flame-retardant heat insulating formed product according to claim 1, wherein the flame retardant is a boric acid or boron.

5. The method of manufacturing a flame-retardant heat insulating formed product according to claim 1, wherein the short fibers with a low melting point are made of polyester, polyethylene or polypropylene.

6. The method of manufacturing a flame-retardant heat insulating formed product according to claim 1, wherein the flame-retardant heat insulating formed product is a mat-shaped formed product.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0017] FIG. 1 contains schematic diagrams to explain a method of manufacturing a flame-retardant heat insulating formed product according to the present invention;

[0018] FIG. 2 is a perspective view of a mat-shaped formed product filled with a heat insulating material as a loose material; and

[0019] FIG. 3 is a cross-sectional view along the line A-A of FIG. 2.

BEST MODE FOR CARRYING OUT THE INVENTION

[0020] A mat-shaped flame-retardant heat insulating formed product will be exemplified as a flame-retardant heat insulating formed product to describe a manufacturing method thereof.

[0021] FIGS. 1A to 1C are schematic diagrams to explain steps up to manufacturing of a flame-retardant heat insulating loose material.

[0022] Further, FIGS. 1D and 1E are schematic diagrams to explain steps up to manufacturing of a forming die made of paper, and FIGS. 1F to 1H are schematic diagrams to explain steps of from filling the prepared forming die made of paper with the flame-retardant heat insulating loose material to obtaining a flame-retardant heat insulating formed product.

Manufacturing of the Flame-Retardant Heat Insulating Loose Material

[0023] In manufacturing of the flame-retardant heat insulating loose material, as shown in FIG. 1A, first, water is poured in used paper or a pulp material to defibrate and obtain defibrated cotton.

[0024] Next, as shown in FIG. 1B, a flame retardant such as boric acid and boron is charged into the defibrated cotton, and by stirring and heating, flame-retardant heat insulating defibrated cotton is obtained.

[0025] Further, as shown in FIG. 1C, short fibers with a low melting point such as polyester, polyethylene and polypropylene are charged into the flame-retardant heat insulating defibrated cotton, and by mixing and stirring, the flame-retardant heat insulating loose material is obtained.

Manufacturing of the Forming Die

[0026] The forming die is provided with a lid having a plurality of air vents, and is configured to be structure where the thickness is thin, as compared with the vertical and horizontal lengths.

[0027] Corrugated cardboard made of paper commonly used in packing and the like is prepared, is subjected to cutting creasing processing according to a development diagram as shown in FIG. 1D as one example, and next, is built to be the forming die made of paper having a lid as shown in FIG. 1E.

[0028] One example of the forming die made of paper is as shown in FIG. 1E, and various shapes are considered as its shape, and are selected as appropriate corresponding to a shape of a required flame-retardant heat insulating formed product.

[0029] It is preferable that the thickness of the corrugated cardboard required of the forming die is about 3 mm in the case where the sum of vertical and horizontal lengths and thickness is about 100 cm, is about 5 mm in the case where the sum ranges from about 100 cm to 150 cm, and is 5 mm or more in the case where the sum is 150 cm or more.

[0030] In addition, in the case of the low number of production lots, corrugated cardboard with a thickness of 3 mm may be used.

Manufacturing of the Flame-Retardant Heat Insulating Formed Product

[0031] As shown in FIG. 1F, after filling the forming die made of paper with the flame-retardant heat insulating loose material and compressing, the lid is put on. The lid of the forming die is to prevent the filled flame-retardant heat insulating loose material from being dissipated from the upper portion, at the time of carrying and at the time of microwave heating.

[0032] Further, the lid of the forming die has an effect of promoting forming by heating, on average, the flame-retardant heat insulating loose material filled with steam heat at the time of microwave heating.

[0033] Next, as shown in FIG. 1G, the lidded forming die filled with the flame-retardant heat insulating loose material is heated with a microwave heating apparatus.

[0034] At the time of microwave heating, moisture of the flame-retardant heat insulating loose material is heated and vaporized. Therefore, the lid of the forming die is provided with air vents for ventilation. It is preferable that the diameter of the air vent is about 5 mm, and that a plurality of vents is provided at intervals ranging from 2 cm to 5 cm.

[0035] The short fiber with a low melting point contained in the flame-retardant heat insulating loose material reaches a melting point by heating at a temperature of 110 C. or more. By fusing of the short fiber with a low melting point, the flame-retardant heat insulating loose material is mutually joined. After heating and forming with the microwave heating apparatus, the mat-shaped formed product is removed from the forming die, and by natural cooling, the mat-shaped flame-retardant heat insulating formed product is obtained as shown in FIG. 1H.

Embodiment

[0036] One example of a manufacturing process of the mat-shaped formed product is as described below.

(1) In 1 kg of used paper or pulp material, water is poured in a weight ratio of 30% to 45%, and the resultant is defibrated for 120 seconds to 300 seconds to be defibrated cotton.
(2) Into the defibrated cotton is charged 150 g of boric acid, the resultant is stirred and heated for 60 seconds to impregnate, and flame-retardant heat insulating defibrated cotton is obtained.
(3) Into the flame-retardant heat insulating defibrated cotton is charged 300 g to 800 g (30% to 80% in a weight ratio) of short fibers with a low melting point, and the resultant is mixed and stirred for 60 seconds to obtain a flame-retardant heat insulating loose material.
(4) A beforehand prepared forming die made of corrugated cardboard provided with a lid having air vents is filled with the flame-retardant heat insulating loose material.
(5) The flame-retardant heat insulating loose material is heated together with the forming die with a microwave heating apparatus at a temperature of 110 C. or more for 120 seconds to 600 seconds.
(6) The flame-retardant heat insulating formed product made the shape of a mat is removed from the forming die, and is subjected to natural cooling.

[0037] In addition, in the present Description, the method of manufacturing a mat-shaped formed pro duct is exemplified and described as the Embodiment, but the formed product according to the present invention is not limited to the mat-shaped product.

[0038] It is needless to say that any appropriate design modification is capable of being made to manufacturing of the flame-retardant heat insulating formed product, without departing from the scope of the claims.