Composite material and producing method of composite material

Abstract

To provide a composite material more lighter and having excellent deodorant effect, and a producing method of a composite material capable of obtaining such composite material.SOLUTION: A composite material 12 includes a porous material 21 and a diatomaceous earth layer 22. The porous material 21 has a plurality of through holes 16 penetrating in a thickness direction. The porous material 21 is formed of paper. The diatomaceous earth layer 22 is a layer in which diatomaceous earth is attached to the porous material 21. The composite material 12 is produced by a soaking process and a drying process. In the soaking process, the porous material 21 is soaked in a dispersion in which powdered diatomaceous earth is dispersed in water. In the drying process, the composite material 12 in which diatomaceous earth adheres to the surface is obtained by drying the porous material 21 that has undergone the soaking process.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a composite material and a method for manufacturing the composite material. [Background technology]

[0002] Panel-shaped composite materials combining a plurality of materials are known. For example, the panel described in Patent Document 1 is used for a sliding door, and includes a core material and two surface materials arranged on both sides of the core material, with a hollow space between the two surface materials. Both surface materials are kenaf fiber boards formed in a lattice or honeycomb shape, and the hollow space is filled with a humidity-regulating material. Examples of the humidity-regulating material include diatomaceous earth, activated carbon, silica gel, zeolite, allophane activated clay, and sepiolite.

[0003] Also, as a panel-shaped composite material that adsorbs odorous components in the air, Patent Document 2 describes a filter element that includes a middle cylinder formed of a roll core, a deodorizing agent filled in the middle cylinder, and a nonwoven fabric. A roll core is used for the middle cylinder, and activated carbon pellets are filled in each cell of the roll core as the deodorizing agent. The nonwoven fabric covers the air inlet surface, air outlet surface, and four peripheral side surfaces of the middle cylinder. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2009-79387 A [Patent Document 2] Utility Model Registration No. 3063411 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the composite materials described in Patent Documents 1 and 2 cannot be said to be lightweight. In addition, a material with an improved odor removal effect is desired.

[0006] Therefore, an object of the present invention is to provide a composite material that is lighter and has an excellent odor removing effect, and a method for producing such a composite material. [Means for solving the problem]

[0007] The composite material of the present invention includes a porous material and diatomaceous earth. The porous material has a plurality of holes penetrating in the thickness direction and is made of paper. The diatomaceous earth is attached to the porous material.

[0008] It is preferable that the surface of the porous material has a diatomaceous earth layer formed in a layered form using diatomaceous earth.

[0009] The porous material is preferably a roll core.

[0010] The porous material may contain a resin.

[0011] The composite material manufacturing method of the present invention includes a soaking step and a drying step. In the soaking step, a porous material formed of paper and having a plurality of holes penetrating in the thickness direction is soaked in a dispersion liquid in which powdered diatomaceous earth is dispersed in water. In the drying step, the porous material that has been subjected to the soaking step is dried to obtain a composite material having diatomaceous earth attached to its surface.

[0012] The dispersion preferably has a water volume in the range of 1 liter to 3 liters per 1 kg of diatomaceous earth. Effect of the Invention

[0013] According to the present invention, a composite material that is lighter in weight and has an excellent odor removing effect can be obtained. [Brief description of the drawings]

[0014] [Figure 1] 1A and 1B are schematic diagrams of a composite unit using a composite material according to an embodiment of the present invention, in which (A) is a schematic plan view and (B) is a schematic cross-sectional view. [Diagram 2] FIG. [Diagram 3]FIG. [Figure 4] FIG. 13 is an explanatory diagram of another porous material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The composite material unit 11 shown in Fig. 1 comprises a panel-shaped composite material 12 and a rectangular frame (frame) 13 in which the composite material 12 is set. The composite material 12 is one embodiment of the composite material of the present invention, and is formed into a rectangle in this example, but can be formed into any shape, such as a circle (including an oval) or a polygon other than a square. The composite material unit 11 can be used in various ways, for example, by leaning it against an indoor wall or by fixing it to the wall. The frame 13 may be formed from various materials such as wood, plastic, metal, etc., and is made of wood in this example.

[0016] Also, in this example, the composite material 12 is set in the frame 13 to form the composite material unit 11, but the composite material 12 may be used alone, for example, by leaning it against a wall, embedding it as part of a wall material inside a room, or placing it in the space under a bed mattress, without using the frame 13. Furthermore, at least one of the panel surfaces 12A, 12B of the panel-shaped composite material 12 may be provided with a breathable sheet (for example, a mesh sheet with a knit pattern, paper such as Japanese paper, etc.) to cover the one panel surface 12A, 12B, thereby improving the design.

[0017] The composite material 12 has a plurality of through holes 16 that penetrate in the thickness direction and form openings on the panel surfaces 12A and 12B. The diameter of the plurality of through holes 16 is generally uniform, but may be non-uniform. The diameter of the through holes 16 is preferably within a range of 8 mm to 20 mm, and is set to about 10 mm in this example. In the example shown in FIG. 1, the through holes 16 are regularly arranged along the panel surfaces 12A and 12B, but may be arranged randomly (irregularly). Note that the composite material 12 in this example has a honeycomb structure in which the arrangement of the through holes 16, specifically, six through holes 16 are located around one through hole 16, but may have a structure other than the honeycomb structure depending on the type of porous material described later and the thickness of the diatomaceous earth layer.

[0018] As shown in Fig. 2, the composite material 12 includes a porous material 21 having a plurality of holes 21a penetrating in the thickness direction, and a diatomaceous earth layer 22 formed in a layer shape from diatomaceous earth. The porous material 21 is made of paper, and as shown in Fig. 3, it is a roll core in which S-shaped members 21b, which are made by bending a long paper sheet into an S-shape, are arranged and joined in a plane. Note that the thickness of the paper forming the porous material 21 is omitted in Fig. 2. By using a roll core as the porous material 21, the composite material 12 has excellent strength.

[0019] The paper constituting the porous material 21 is not particularly limited, and for example, kraft paper can be used. The thickness of the paper is also not particularly limited. The paper constituting the porous material 21 may contain resin, and the resin can be contained by impregnation treatment. By using the porous material 21 formed from paper containing resin, a composite material 12 with improved strength etc. can be obtained, but whether or not to contain resin can be determined depending on the application of the composite material 12. The roll core may be a commercially available product, and in this example, a commercially available product (roll core manufactured by Shin-Nihon Feather Core Co., Ltd.) is used.

[0020] The diatomaceous earth layer 22 is formed by powdered diatomaceous earth adhering to the paper of the porous material 21. The particle size of the diatomaceous earth is not particularly limited, but from the viewpoint of manufacturability in the manufacturing method described below, a particle size corresponding to a range of 100 mesh or more and 300 mesh or less according to the ASTM (American Society for Testing and Materials) standard is preferable, and in this example, a particle size corresponding to 200 mesh is used. The shape of the diatomaceous earth particles does not need to be a sphere with a perfectly circular cross section, and in this example, they are also irregular. Note that when the diatomaceous earth used contains diatomaceous earth with an extremely small particle size, these fine particles may get inside the paper of the porous material 21.

[0021] The diatomaceous earth layer 22 is formed by adhering diatomaceous earth to the paper surface of the porous material 21, and there is no particular limitation on the thickness. When a roll core is used as the porous material 21, various types of composite materials can be obtained depending on the thickness of the diatomaceous earth layer 22, such as obtaining a honeycomb-structured composite material 12 by making the diatomaceous earth layer 22 thicker, or obtaining a composite material (not shown) in the shape of a roll core rather than a honeycomb structure by making the diatomaceous earth layer 22 thinner.

[0022] The composite material 12 includes a diatomaceous earth layer 22 formed of diatomaceous earth, which is a porous body. The diatomaceous earth layer 22 is provided as a thin film on the surface of the partition walls that define the holes 21a of the porous material 21, and is therefore extremely light compared to the case where the diatomaceous earth layer 22 is filled into the holes 21a. In addition, since the diatomaceous earth layer 22 is provided on the surface of the paper that constitutes the porous material 21, including the surface of the partition walls, the exposed area exposed to the outside air is extremely large compared to the case where the diatomaceous earth layer 22 is provided on the surface of a paper sheet and the case where the diatomaceous earth layer is filled into the holes 21a. Therefore, the effect of removing the odor of the outside air is superior. In this way, the three-dimensional composite material 12 has the diatomaceous earth layer 22 formed three-dimensionally, and therefore the effective area for removing the odor of the outside air is three times or more larger than the case where the diatomaceous earth layer is provided on the surface of a paper sheet with the same area occupied by installation, and thus exhibits an extremely high effect. Furthermore, this composite material 12 not only removes odors from the outside air, but also has an extremely high effect in regulating humidity, including reducing humidity.

[0023] The diatomaceous earth is not particularly limited, and can be produced in various places such as Akita, Ishikawa, Hokkaido, and Shimane. Among them, from the viewpoint of odor removal effect, Wakkanai Formation siliceous shale produced in Hokkaido is most preferable. 2 Two types of composite material 12 of the present example and one type of composite material as a comparative example were placed in a smoking room of 1.44 m2, and the odor removing effect was evaluated. 2 The composite material as a comparative example had an activated carbon layer formed from activated carbon instead of the diatomaceous earth layer 22, and even after 10 days had passed since placement, no odor removal effect was felt. One example of the composite material 12 (Example 1) had the diatomaceous earth layer 22 formed from diatomaceous earth produced in Noto, Ishikawa Prefecture, and 10 days after placement, no odor was detected, and an effect was obtained. Another example of the composite material 12 (Example 2) had the diatomaceous earth layer 22 formed from siliceous shale produced in Wakkanai, Hokkaido, and 4 days after placement, no odor was detected, and an extremely high effect was obtained.

[0024] The diatomaceous earth layer 22 may contain other materials in addition to diatomaceous earth. Examples of other materials include slaked lime and burned scallops (burned scallop shells), and these may be used in combination. The mass of the slaked lime and burned scallops in the diatomaceous earth layer 22 may be greater than the mass of the diatomaceous earth. For example, it has been confirmed that a sufficient odor removal effect can be achieved even if the mass of the diatomaceous earth layer 22 is 100, the mass of the slaked lime is 37, and the mass of the burned scallops is 53. The particle size of the slaked lime is not particularly limited, and may be the same as or different from the above particle size range of the diatomaceous earth. For example, various particle sizes can be used, such as a mixture of slaked lime having particle sizes corresponding to 200 mesh and 300 mesh in the ASTM standard, and burned scallops having a size within the range of 100 mesh to 200 mesh in the ASTM standard.

[0025] The porous material 21 can be replaced with other porous materials. As another example, a honeycomb-structured porous material 31 shown in Fig. 4 can be used. The porous material 31 has a plurality of regular hexagonal holes 31a arranged in a close-packed manner in the surface direction. As another example, a bias core manufactured by Asahi Chushin Co., Ltd. can be used as the porous material.

[0026] The composite material 12 can be manufactured, for example, by the following manufacturing method. That is, this manufacturing method includes a soaking step and a drying step. In the soaking step, the porous material 21 (see FIG. 2) is soaked in a dispersion liquid in which powdered diatomaceous earth is dispersed in water. When a porous material other than the porous material 21 is used, it is soaked in the same manner. The dispersion liquid is preferably such that the volume of water is in the range of 1 liter to 3 liters per 1 kg of diatomaceous earth, and in this example, for example, the volume of water is 2 liters per 1 kg of diatomaceous earth. When forming the diatomaceous earth layer 22 containing slaked lime and burnt scallops, it is preferable to disperse these powders in water to prepare the dispersion liquid.

[0027] In the drying step, the porous material 21 that has been subjected to the immersion step is dried to obtain the composite material 12 having the diatomaceous earth attached to its surface. The drying process is preferably performed at room temperature (approximately 25°C). The thickness of the diatomaceous earth layer 22 may be increased by repeatedly performing the immersion step and the drying step. [Explanation of symbols]

[0028] 11 Composite Unit 12 Composite materials 21,31 Porous materials 21a,31a hole 22 Diatomaceous earth layer

Claims

1. A porous material formed of paper and having a plurality of holes penetrating in a thickness direction; Diatomaceous earth attached to the porous material; A composite material comprising:

2. 2. The composite material according to claim 1, further comprising a diatomaceous earth layer formed on a surface of the porous material in a layered form using the diatomaceous earth.

3. The composite material according to claim 1 or 2, wherein the porous material is a roll core.

4. The composite material according to claim 1 or 2, wherein the porous material contains a resin.

5. an immersion step of immersing a porous material formed of paper and having a plurality of holes penetrating in a thickness direction, in a dispersion liquid in which powdered diatomaceous earth is dispersed in water; a drying step of drying the porous material after the immersion step to obtain a composite material having the diatomaceous earth attached to the surface; A method for manufacturing a composite material comprising the steps of:

6. 6. The method for manufacturing a composite material according to claim 5, wherein the dispersion has a volume of water in the range of 1 liter or more and 3 liters or less per 1 kg of the mass of the diatomaceous earth.

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