Method And Apparatus For Producing Fiber Molded Article, Fiber Molded Precursor, And Fiber Molded Article

Abstract

A method of producing a fiber molded article including the steps of forming a wet fiber deposit layer ( 10 ) from a fiber material-containing slurry by papermaking processing and pressing the fiber deposit layer ( 10 ) to give a fiber molded article having an edge ( 113 ) where two faces ( 111 and 112 ) meet. A thick-walled part ( 104 ) is formed near the edge ( 113 ), which is pressed to form the edge ( 113 ). The forming mold used in the pressing is preferably heated. The thick-walled part ( 104 ) is preferably formed by partly bending the fiber deposit layer ( 10 ).

1 . A method of producing a fiber molded article having a mating face with an edge, the mating face being adapted to be joined with a mating face of another fiber molded article, the method including the steps of forming a fiber deposit layer containing a fiber material by papermaking processing and pressing the fiber deposit layer, wherein the fiber deposit layer has a thick-walled part at or near the edge, and the thick-walled part is pressed in the step of pressing. 
   
   
       2 . The method of producing a fiber molded article according to  claim 1 , wherein the fiber deposit layer is a wet fiber deposit layer obtained by papermaking processing using slurry containing the fiber material, and the edge is formed where two faces meet. 
   
   
       3 . The method of producing a fiber molded article according to  claim 1  or  2 , wherein the step of pressing is carried out using a heated forming mold. 
   
   
       4 . The method of producing a fiber molded article according to  claim 3 , wherein the forming portion of the forming mold is coated with a fluororesin. 
   
   
       5 . The method of producing a fiber molded article according to  claim 1 , wherein the thick-walled part is formed by partly bending the fiber deposit layer. 
   
   
       6 . The method of producing a fiber molded article according to  claim 5 , wherein when the fiber deposit layer is removed from a papermaking mold, the outer peripheral portion of an overhang of the fiber deposit layer providing the mating face is released from the papermaking mold to bend the basal part of the overhang. 
   
   
       7 . A method of producing a fiber molded article having a mating face with an edge, the mating face being adapted to be joined with a mating member, the method including the steps of forming a fiber deposit layer containing a fiber material by papermaking processing and pressing the fiber deposit layer, wherein the fiber deposit layer has a thick-walled part at or near the edge, and the thick-walled part is pressed in the step of pressing. 
   
   
       8 . A papermaking mold used in the method of producing a fiber molded article according to  claim 1 , which forms the thick-walled part at where two faces of the fiber deposit layer meet. 
   
   
       9 . A papermaking mold used in the method of producing a fiber molded article according to  claim 1 , having, in a papermaking portion thereof on which the fiber deposit layer is to be formed, a recess for forming the thick-walled part, the recess being formed by providing a base part of the papermaking portion at a position lower than a parting face of the papermaking mold. 
   
   
       10 . A papermaking mold used in the method of producing a fiber molded article according to  claim 1 , having, on a papermaking portion thereof on which the fiber deposit layer is to be formed, a groove for forming the thick-walled part. 
   
   
       11 . Apparatus for carrying out the method of producing a fiber molded article according to  claim 6 , comprising a papermaking mold for forming the fiber deposit layer and a receiving mold for receiving the fiber deposit layer from the papermaking mold, the papermaking mold or the receiving mold having thick-walled part-forming means for bending the basal part of the overhang to make the thick-walled part. 
   
   
       12 . The apparatus for producing a fiber molded article according to  claim 11 , wherein the thick-walled part-forming means comprises (1) separation means for separating the outer peripheral portion of the overhang from the papermaking mold when the papermaking mold and the receiving mold are joined together and (2) a space-forming portion for providing a space between the papermaking mold and the receiving mold in which the basal part is bent. 
   
   
       13 . A fiber molded precursor used in the production of a fiber molded article having a mating face with an edge, the mating face being adapted to be joined with a mating fiber molded article or a mating member, comprising a wet fiber deposit layer formed from a slurry containing a fiber material by papermaking processing and having a thick-walled part formed by partly bending the fiber deposit layer along or near the edge of the fiber deposit layer corresponding to the edge of the fiber molded article. 
   
   
       14 . A fiber molded article obtained by forming a fiber deposit layer containing a fiber material by papermaking processing and pressing the fiber deposit layer, the fiber molded article having a sharp edge where two faces thereof meet. 
   
   
       15 . The fiber molded article according to  claim 14 , wherein the edge has a curvature radius of 1 mm or smaller. 
   
   
       16 . A fiber molded article having a mating face with a sharp edge, the mating face being adapted to closing against another fiber molded article to form a cavity. 
   
   
       17 . The fiber molded article according to  claim 16 , the edge of the mating face has a curvature radius of 1 mm or smaller.