KR101784236B1 - Glass fiber mat for construction, manufacturing method and manufacturing apparatus thereof - Google Patents

Abstract

The present invention relates to a glass fiber mat for construction, a method of manufacturing the same and an apparatus for manufacturing the same, which comprises a meta-aramid fiber web layer (A) made of meta-aramid fiber, an activated carbon fiber web layer (B) made of activated carbon fiber, A glass fiber web layer (C), and a carbon fiber web layer (D) made of carbon fiber are successively laminated and transported, needle punching is carried out to form mutually entangled multilayer aggregates, and then both sides of the multilayer aggregate are cut and wound, And has a deodorizing function while being excellent in flame retardancy, thereby making it possible to manufacture a glass fiber mat for architectural use excellent in tantalum ratio and merchantability.

Description

Technical Field [0001] The present invention relates to a glass fiber mat for construction,

The present invention relates to a glass fiber mat for construction, a method of manufacturing the same, and a manufacturing apparatus thereof. More particularly, the present invention relates to a glass fiber mat for construction, and more particularly to a multi- The present invention also relates to a manufacturing method and a manufacturing apparatus for a glass fiber mat for construction.

Glass fiber is a glass fiber mainly composed of silicate, which is processed into a fiber shape by melting and processing, and is also referred to as glass fiber or glass wool.

These glass fibers are excellent in heat resistance, corrosion resistance, moisture resistance, heat insulation, sound absorption and the like, and as the diameter of the glass fiber becomes smaller, the tensile strength and flexibility increase. Therefore, the reinforcing plastic raw material, electric insulating material, It is widely used in a wide variety of industrial fields such as soundproofing, insulation, decorative fabrics, and manure.

Particularly, when glass fiber is manufactured into a nonwoven fabric by needle punching, it can be used as a thermal insulation material for construction. The conventional technology for manufacturing thermal insulation material and manufacturing apparatus using glass fiber will be described as follows.

In Patent Document 10-1996-0037599, thermally fusible fibers having a melting point of about 100 to 170 ° C of long glass fibers are mixed at a weight ratio of about 90 to 99%: 10 to 1%, molded to a proper thickness, (100% Spun Bond) nonwoven fabric. The thermosetting resin liquid is sprayed on the bottom surface of the nonwoven fabric, and fixed to the bottom surface through a drying chamber. The thermosetting resin liquid is heated again to a temperature higher than the melting point of the heat- And passing through the formed upper and lower forming rollers, thereby producing a construction glass fiber mat (MAT).

In addition, Registration Utility Model No. 20-0252982 discloses a glass fiber mat excellent in thermal insulation performance, which is interposed between upper and lower glass fiber fabrics to be placed in a vertical direction, and which is connected to a glass fiber yarn Glass fiber fabric; And a glass fiber mat comprising a thermosetting resin impregnated in the glass fiber fabric.

As described above, the conventional glass fiber mat is generally manufactured by blowing a liquid thermosetting resin through a needle punching process to form a glass fiber mat by increasing the bonding force between the tissues by drying and curing the same.

Generally, building materials are required to have fire resistance and flame retardancy in order to prevent fire and to prevent the spread of flame. However, the thermosetting resin used in the conventional glass fiber mat as described above is a phenol resin, poly Ester resin, epoxy resin, or the like is mainly used, the glass fiber mat has a heat resistance of about 300 캜 or less.

In other words, the temperature at which most building fires occur exceeds 300 ° C, which is the state-keeping temperature limit of conventional glass fiber mats, so that when the fire occurs, the glass fiber mat melts down, There is a disadvantage in that it is not a practical help to prevent the problem.

In order to solve the disadvantages of the above-mentioned low-temperature-resistant glass fiber mat, a mat made of 100% of silica fibers superior in heat resistance to glass fiber is produced. However, since the production cost of the silica fiber is seven times that of the glass fiber, In the case of producing a mat using fibers alone, the manufacturing cost is too high, and generally, only low-density web-type products are produced, which causes drawbacks that are vulnerable to moisture.

That is, although the silica fiber itself is strong against humidity, when the state of moisture penetration is maintained for a long time in a state where the silica fiber is constituted of a low density mat type, the mat having a low density is recessed by the moisture, However, even if the moisture evaporates once the mat rests, there is a disadvantage in that the recessed mat is not restored to the original shape, resulting in an insulation defect.

Japanese Patent Application Laid-Open No. 10-2015-0034407 Japanese Patent Application Laid-Open No. 10-2015-0126574

The present invention has been made in order to solve the problems of the prior art as described above, and it is an object of the present invention to provide a web made of a different material including glass fibers as a multilayered mat, and then integrated by needle punching, And has excellent deodorizing function and excellent commercial properties that do not sink even when exposed to moisture for a long time, and a manufacturing method and a manufacturing apparatus for the same.

In order to accomplish the above object, the present invention provides a method for producing a glass fiber mat for architectural use, which comprises a meta-aramid fiber having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm, A first step (S1) of continuously forming the web layer (A) with a 10 to 30 mm-thick meta-aramid fiber web layer having the same orientation; Activated carbon fibers having a fiber diameter of 7 to 15 占 퐉, a surface area of 1,100 to 1,600 m2 / g, and a fiber length of 40 to 80 mm were laminated in an air-laid manner to an activated carbon fiber web layer B); A third step of successively molding glass fibers having a fiber diameter of 6 to 12 탆 and a fiber length of 40 to 100 mm in a glass fiber web layer (C) having a machine direction fiber bundle having a thickness of 100 to 150 mm S3); A fourth step S4 of continuously forming carbon fibers having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm in a carding manner into a carbon fiber web layer D having a cross direction fiber orientation of 10 to 20 mm in thickness, ; The fibers are sequentially stacked on the conveying conveyor 50 such that the fiber orientation properties of the meta-aramid fiber web layer A, the activated carbon fiber web layer B, the glass fiber web layer C and the carbon fiber web layer D are mutually interchanged, A fifth step S5; A sixth step (S6) of needle-punching the multi-layered web layers to form a multi-layer mat having a thickness of 10 to 30 mm and a density of 90 to 110 kg / m < 3 > A seventh step (S7) of cutting both sides of the multi-layered mat so that the multi-layered mat has a predetermined width; An eighth step (S8) of drying the multi-layered mat with both edges cut off; And a ninth step (S9) of winding the cut multilayer mat into a roll form.

The meta-aramid fiber web layer (A) is supplied to a carding machine using meta-aramid fibers having a fiber diameter of 6 to 10 mu m and a fiber length of 40 to 80 mm to form a meta-aramid fiber web layer (A) having cross- The meta-aramid fiber web layer (A) is laminated in a zig-zag manner using a cross-rapping machine (105) and has a basis weight of 100 to 150 g / m 2 and a thickness of 20 to 40 mm, And a meta-aramid fiber web layer (A) having a temperature of 1,000 to 1,200 ° C is formed.

The active carbon fiber web layer (B) is obtained by supplying activated carbon fibers having a fiber diameter of 7 to 15 탆, a surface area of 1,100 to 1,600 m 2 / g and a fiber length of 40 to 80 mm to an air- And an activated carbon fiber web layer (B) having a thickness of 20 to 40 mm within a range of a basis weight of 50 to 100 g / m < 2 > at a speed of 1,500 rpm and a suction speed of 3,000 to 4,000 rpm.

The glass fiber web layer (C) was prepared by mixing E-glass long fiber yarn (YARN) having a fiber diameter of 6 to 12 탆 and a fiber length of 40 to 100 mm at a ratio of 5: 5, A glass fiber web layer (100 g / m < 2 >) having a thickness of 100 to 150 mm and a heat-resistant temperature of 400 to 650 deg. C at a cylinder speed of 500 to 600 rpm and a suction speed of 3,000 to 4,000 rpm C) is formed.

The carbon fiber web layer (D) is obtained by supplying a carbon fiber having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm to a carding machine to produce a sheet having a thickness of 10 to 20 mm, And a carbon fiber web layer (D) satisfying a temperature of 800 to 1,200 占 폚 is formed.

Wherein the carbon fiber web layer (D) comprises carbon fiber having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm, a carbon fiber having a fiber diameter of 6 to 12 탆, a fiber length of 40 to 100 mm, Roving is mixed at a ratio of 7: 3 and fed to a carding machine to form a carbon fiber web layer (D) having a thickness of 10 to 20 mm and a heat resistance temperature of 800 to 1,200 ° C within a range of a basis weight of 80 to 120 g / .

The carbon fiber web layer (D) comprises carbon fiber having a fiber diameter of 6 to 10 탆 and a length of 40 to 80 mm, E-glass fiber roving having a fiber diameter of 6 to 12 탆 and a length of 40 to 100 mm The mixture was fed to an air-laid machine at a cylinder speed of 1,200 to 1,500 rpm and a suction speed of 3,000 to 4,000 rpm to a basis weight of 80 to 120 g / Mm and a heat-resistant temperature of 800 to 1,200 占 폚.

On the other hand, the apparatus for producing a glass fiber mat for architectural use of the present invention comprises a meta-aramid fiber web (A) having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm in a carding manner in a thickness of 10 to 30 mm A first line (10) for continuous discharge; Activated carbon fibers having a fiber diameter of 7 to 15 占 퐉, a surface area of 1,100 to 1,600 m2 / g and a fiber length of 40 to 80 mm are formed by an air-laid method into an activated carbon fiber web layer (B) A second line (20) for discharging; A third line 30 in which glass fibers having a fiber diameter of 6 to 12 占 퐉 and a fiber length of 40 to 100 mm are formed in a glass fiber web layer (C) having a thickness of 100 to 150 mm by an airlaid method and continuously discharged; A fourth line 40 in which carbon fibers having a fiber diameter of 6 to 10 占 퐉 and a fiber length of 40 to 80 mm are formed in a carding web of a carbon fiber web layer D having a thickness of 10 to 20 mm and continuously discharged; The meta-aramid fiber web layer (A), the activated carbon fiber web layer (B), the glass fiber web layer (C), and the carbon fiber web layer (D) successively discharged from the first, second, third and fourth lines A conveying conveyor 50 for stacking and conveying at one time; A needle punching machine (60) configured by needle punching the multi-layered web layers conveyed by the conveying conveyor (50) to constitute a multi-layered mat having a mutual entangled thickness; A waterjet cutter (70) for continuously cutting both side edges of the needle punched multi-layered mat in the longitudinal direction to adjust the width and cutting the multi-layered mat to a predetermined length; A dryer (80) for drying the multi-layered mat with both side edges cut by the waterjet cutter (70); And a winding machine 90 for winding the dried multi-layer mat.

The first line 10 includes a first opener 101 for releasing meta-aramid fibers cut to a predetermined length and continuously supplied; A first blow machine 102 for feeding the meta-aramid fibers discharged from the first opener 101 by using wind; A first mix tank 103 for storing and mixing the meta-aramid fibers supplied through the first blow machine 102 and discharging meta-aramid fibers through a plurality of outlets; A first carding machine 104 forming a meta-aramid fiber web layer A having a predetermined thickness by a carding method and continuously discharging meta-aramid fibers discharged in a predetermined amount from the first mix tank 103; And a crossing machine 105 for successively laminating the meta-aramid fiber web A continuously discharged in the first carding machine 104 in a zigzag manner.

The second line (20) includes a second opener (201) for loosening activated carbon fibers continuously cut to a predetermined length and supplied continuously; A second blow machine 202 for feeding the activated carbon fibers discharged from the second opener 201 by wind; A second mix tank 203 for storing and simultaneously discharging the activated carbon fibers supplied through the second blow machine 202 in a fixed amount; And a second air laid machine 204 for forming the activated carbon fiber web B having a predetermined thickness by using an air flow method and continuously discharging the activated carbon fiber to be discharged in a constant amount.

The third line (30) includes a third opener (301) for loosening the glass fibers continuously cut to a predetermined length and being supplied; A third blow machine 302 for feeding the glass fiber discharged and discharged from the third opener 301 by wind; A third mix tank 303 for storing and simultaneously discharging the glass fibers supplied through the third blowing machine 302 in a fixed amount; And a third air-laid machine 304 for forming a glass fiber web C having a predetermined thickness by using an air flow method and continuously discharging the glass fibers discharged in a constant amount.

The fourth line (40) includes a fourth opener (401) for loosening carbon fibers continuously cut to a predetermined length and being supplied continuously; A fourth blow machine 402 for feeding the carbon fibers discharged from the fourth opener 401 by using wind; A fourth mix tank 403 for storing the carbon fibers supplied through the fourth blow machine 402 and discharging the mixed carbon fibers in a fixed amount; And a second carding machine 404 for continuously discharging the carbon fibers discharged in a predetermined amount from the fourth mix tank 403 into a carbon fiber web layer D having a predetermined thickness by a carding method.

The conveying conveyor 50 includes a meta-aramid fiber web layer A, an activated carbon fiber web layer B, a glass fiber web layer C, A guide wall 501 having a predetermined height is formed on both sides of the web layer D so as to align the multi-layered web layer on both sides of the web layer D in order to laminate the web layer D sequentially.

The needle punching machine 60 is equipped with needles of 2,000 to 4,500EA / m, needle-punched at a rotation speed of 200 to 600 rpm, a speed of 2 to 4 m / min and a taming degree of 40 to 60 times / cm, And a second needle punching is performed from the lower part to the upper part after the first needle punching to the lower part.

The construction glass fiber mat of the present invention is constituted by a multi-layer multi-layered mat wrapped with a meta-aramid fiber web layer, an activated carbon fiber web layer, and a carbon fiber web layer on the inner and outer surfaces of a glass fiber web layer having a predetermined thickness, So that it is possible to use the convenience of the construction and various construction methods.

In addition, a glass fiber web layer with excellent heat resistance and heat insulation is wrapped in a web layer of a meta-aramid fiber and a carbon fiber web layer, which are excellent in nonflammability and flame retardancy, so as to prevent the spread of fire through excellent incombustibility, flame- It is effective to extinguish fire safety.

Further, since the activated carbon fiber web layer is provided, it is excellent in deodorizing function for removing various odors contained in the air inside the building during construction of the building, and also keeps indoor air inside the building pleasant by collecting fine dust inside the building And prevents the moisture from entering into the glass fiber web layer due to the excellent moisture-proof property of the activated carbon fiber web layer, thereby preventing the aging of the glass fiber due to moisture and prolonging the service life.

In addition, the glass fiber mat for construction of the present invention has a glass fiber web layer having excellent heat resistance and heat insulation as a core, and the meta-aramid fiber web layer and the carbon fiber web layer, which are more expensive than the glass fiber web layer, So that it is advantageous in terms of merchantability as a building interior material because it has excellent heat insulation property, incombustibility, flame retardancy, sound-absorbing property and deodorizing property at the same time.

Also, in the process of laminating multi-layered webs of different materials and needle-punching and mutual entanglement, the fiber orientation of each web layer is alternately laminated, thereby greatly improving the bulkiness and form stability of the matted glass fiber mat by needle punching .

In addition, since the nonwoven fabric as a transfer material is produced at a time, and the products are formed in a mat form by laminating them in a multilayer structure and needle punching all at once, not only the manufacturing process is simplified, the working speed and productivity are greatly improved, The working environment is greatly improved, and compared with a complicated product structure, the construction of the manufacturing apparatus for producing the product is efficient and simple, the maintenance and management of the manufacturing apparatus is easy, and the manufacturing cost is also low .

Accordingly, the glass fiber mat for construction of the present invention can be used for various building interior and exterior materials such as sound absorbing materials for civil engineering construction, thermal insulating materials for civil engineering construction, protective coatings for civil engineering construction, dustproof materials for civil engineering construction, soundproofing materials for civil engineering construction, dustproof soundproofing materials for hot water pipes, It is effective.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing a process sequence according to an embodiment of a method for manufacturing a glass fiber mat for construction of the present invention. FIG.
BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a glass fiber mat,
3 is a schematic view showing a process for manufacturing a glass fiber mat for construction according to an embodiment of a method for manufacturing a glass fiber mat for construction and a manufacturing apparatus of the present invention
4 is a view showing a glass fiber mat for construction produced according to an embodiment of the method and apparatus for manufacturing glass fiber mat for construction of the present invention.

The present invention relates to a glass fiber mat for construction, and a manufacturing method and a manufacturing apparatus for the same. The glass fiber mat for construction of the present invention comprises a meta-aramid fiber web layer (A) made of meta-aramid fiber, an activated carbon fiber web layer B, a glass fiber web layer C made of glass fiber, and a carbon fiber web layer D made of carbon fiber are successively laminated and transported while being needle punched to form mutually entangled multilayer mat, The glass fiber mats of the present invention for producing the architectural glass fiber mat of the present invention can be obtained by cutting the both sides of the glass fiber mat of the present invention and then winding it thereon and winding it to produce a glass fiber mat having excellent noncombustibility and flame- The manufacturing method of the fiber mat will be described in more detail as follows.

The present invention relates to a first step (S1) of continuously forming meta-aramid fibers into a meta-aramid fiber web (A) having a thickness of 10 to 30 mm in a carding manner; A second step (S2) of continuously forming the activated carbon fibers into an activated carbon fiber web layer (B) having a thickness of 20 to 40 mm by an air-laid method; A third step (S3) of successively molding the glass fibers into a glass fiber web layer (C) having a thickness of 100 to 150 mm by an air-laid method; A fourth step (S4) of continuously forming the carbon fibers into a carbon fiber web layer (D) having a thickness of 10 to 20 mm by a carding method; The fibers are sequentially stacked on the conveying conveyor 50 such that the fiber orientation properties of the meta-aramid fiber web layer A, the activated carbon fiber web layer B, the glass fiber web layer C and the carbon fiber web layer D are mutually interchanged, A fifth step S5; A sixth step (S6) of needle-punching the multi-layered web layers to form a multi-layer mat having a thickness of 10 to 30 mm and a density of 90 to 110 kg / m3; A seventh step (S7) of cutting both sides of the multi-layered mat so that the multi-layered mat has a predetermined width; An eighth step (S8) of drying the multi-layered mat with both edges cut off; And a ninth step (S9) of winding the cut multilayer mat into a roll form.

In the first step S1, meta-aramid fibers having a fiber diameter of 6 to 10 mu m are cut to a length of 40 to 80 mm for continuous molding of the meta-aramid fiber web layer A, The meta-aramid fiber is supplied to a mixing tank through a blow machine and is continuously discharged in a constant amount and supplied to a carding machine.

The carding machine continuously forms the meta-aramid fibers supplied from the mixing tank with a meta-aramid fiber web layer (A) having a predetermined thickness.

In general, the carding machine moves from the feed plate to the grooved home rollers and feed rollers and slowly receives the fibers. There is a walker on the left and right of the swift, and the fancy rotates at high speed to float the fibers on the cylinder behind the swift and licker. The doffer installed behind the cylinder rotates counterclockwise and the surface speed is lower than that of the swift so that the fibers are peeled from the swift and rotated at a high speed so that the percome combs it and drops the separated fibers into a continuous sheet of thin sheet The web is formed. Therefore, the web produced by the carding machine is arranged in the cross direction with the fiber orientation regardless of the production width.

Therefore, in order to control the fiber orientation of the meta-aramid fiber web layer (A), a cross-lapping machine (CROSS LAPPING MACHINE) is installed behind the carding machine to form a meta-aramid fiber web layer And a meta-aramid fiber web layer (A) having a thickness of 20 to 40 mm and a heat-resistant temperature of 1,000 to 1,200 ° C, both having a mechanical direction and a cross direction fiber orientation, are formed.

Aramid fibers called aromatic polyamides are high-performance heat-resistant materials that can be used continuously at a decomposition temperature of 400 DEG C and above 160 DEG C, and the polymer itself has excellent flame retardancy.

Aramid refers to a synthetic polymer with a proposed name of 85% or more of amide groups (-CONH-) bonds directly connected to two aromatic rings, distinguished from nylon, which is an aliphatic polyamide.

Aramid has been studied and developed for many years with heat-resistant or high-strength fibers. It is divided into meta-aramid (m-Aramid) and para-aramid (p-aramid).

The m-aramid fiber is characterized by high heat resistance and excellent flame retardancy. In terms of flame retardance, the LOI value (limit oxygen index = the minimum oxygen concentration required for the material to sustain combustion, (2) the ignition point is higher than 800 ° C and the flash point is 615 ° C, (3) the carbon monoxide is 536ppm and the carbon dioxide is 370ppm when burned, And there is no melting or dripping during combustion.

Therefore, when it is used as a building interior material, not only the effect of preventing the spread of fire when a fire occurs inside the building is excellent, but also it is possible to secure the time required for the evacuation of people, It is possible to reduce the damage.

In the second step S2, activated carbon fibers having a fiber diameter of 7 to 15 mu m and a surface area of 1,100 to 1,600 m < 2 > / g are cut to a length of 40 to 80 mm to continuously form the activated carbon fiber web layer (B) When the carbon fibers are continuously supplied to the opener, the carbon fibers are supplied to a mixing tank through a blowing machine and dispersed. The carbon fibers are continuously discharged in a constant amount and supplied to an air-laid machine.

The activated carbon fiber supplied to the air-laid machine is subjected to a heat treatment at a cylinder speed of 1,200 to 1,500 rpm and a suction speed of 3,000 to 4,000 rpm to a weight of 70 to 120 g / The fibrous orientation of the activated carbon fiber web layer B is formed in a cross direction by adjusting the flow rate of the air in the air-laid machine and the direction of spraying.

Since the activated carbon fiber has a very large surface area and has a fine pore structure of uniform pore size, it is advantageous in that it is very light in weight and is easy to handle, and also has a very high adsorption rate at an adsorption rate , The deodorization of living air and the removal of fine dust are excellent.

Therefore, when the activated carbon fiber web layer (B) is directed to the interior of the building, it has the advantage of keeping air inside the building pleasantly through the purification ability against the air inside the building.

In the third step S3, an E-glass filament yarn (YARN) having a fiber diameter of 6 to 12 μm and a roving are cut to a length of 40 to 100 mm to continuously form the glass fiber web layer (C) The carbon fibers are fed to a mixing tank through a blow machine and dispersed. The carbon fibers are then continuously discharged in a constant amount and supplied to an air-laid machine.

A glass fiber web C having a thickness of 100 to 150 mm is formed within a range of a basis weight of 150 to 200 g / m < 2 > at a cylinder speed of 500 to 600 rpm and a suction speed of 3,000 to 4,000 rpm .

At this time, the fiber orientation of the glass fiber web layer (C) is formed in the machine direction through adjustment of the air flow rate and injection direction of the air laid machine, and the heat resistant temperature satisfies 400 to 650 ° C.

The glass fiber is formed by melting the raw material and then making it into a glass film having a diameter of about 1.5 to 2 cm. The glass fiber is made into a very thin filament having a fiber diameter of 6 to 12 μm through 'melt spinning' A bundle of 4,000 copies is referred to as a strand. A yarn with a twist is called a yarn (YARN), and a bundle of tens of yarns without twisting a strand is called a roving.

The glass fiber is thin and has a very large specific surface area. Therefore, it has a chemical composition which is not eroded well by moisture, and is excellent in chemical resistance because it has acid resistance and alkali resistance. Especially, E-glass has alkali oxide such as sodium, Less than 1%, and is characterized by excellent weather resistance, electrical insulation, chemical resistance, and excellent quality without alkali.

In the fourth step S4, the carbon fiber having a fiber diameter of 6 to 10 탆 is cut to a length of 40 to 80 mm in order to continuously form the carbon fiber web layer (D), and then continuously inserted into the opener. Is supplied to a mixing tank through a blowing machine and dispersed, and then continuously discharged in a constant amount and supplied to a carding machine.

The carbon fiber supplied from the mixing tank is formed by a carding machine into a carbon fiber web layer (D) having a thickness of 10 to 20 mm within a range of a basis weight of 80 to 120 g / m 2 and continuously discharged. At this time, The fiber orientation is formed in the cross direction and satisfies the heat resistance temperature of 800 to 1,200 占 폚.

As another embodiment of the fourth step (S4), in order to continuously form the carbon fiber web layer (D), carbon fibers having a fiber diameter of 6 to 10 탆 and a length of 40 to 80 mm and carbon fibers having a fiber diameter of 6 to 12 탆 and a length of 40 to 100 mm were mixed at a ratio of 7: 3 and continuously introduced into an opener. The carbon fiber mixture thus charged was supplied to a mixing tank through a blow machine and mixed , And is continuously discharged in a constant amount and supplied to the carding machine.

The carbon fiber mixture supplied from the mixing tank is formed by a carding machine into a carbon fiber web layer (D) having a thickness of 10 to 20 mm in a weight of 80 to 120 g / m < 2 > Is formed in the cross direction and satisfies the heat resistance temperature of 800 to 1,200 占 폚.

As another embodiment of the fourth step (S4), in order to continuously form the carbon fiber web layer (D), carbon fibers having a fiber diameter of 6 to 10 탆 and a length of 40 to 80 mm and carbon fibers having a fiber diameter of 6 to 12 탆 and a length of 40 to 100 mm were mixed at a ratio of 7: 3 and continuously introduced into an opener. The carbon fiber mixture thus charged was supplied to a mixing tank through a blow machine and mixed , Continuously discharged in a constant amount, and supplied to an air-laid machine.

The carbon fiber mixture supplied to the air-laid machine has a cylinder speed of 1,200 to 1,500 rpm and a suction speed of 3,000 to 4,000 rpm at a basis weight of 80 to 120 g / The fiber orientation of the carbon fiber web layer D is formed in the cross direction by adjusting the flow rate of air and the direction of air of the air-laid machine, and the heat resistance temperature is 800 to 1,200 ° C. Satisfies.

The carbon fiber is obtained by heat-treating the organic fiber in an inert gas at an appropriate temperature and then crystallizing the carbon fiber. In the heating process, molecules such as oxygen, hydrogen, and nitrogen escape from the metal, (Iron) is superior in strength and elasticity, there is no concern about corrosion.

Accordingly, the inner carbon fiber web layer (A) formed by using the carbon fiber has excellent nonflammability and heat resistance, thereby suppressing the propagation and diffusion of the flame when a fire occurs inside the building, thereby protecting the wall, Thereby demonstrating excellent fire safety that prevents collapse of buildings due to fire.

In addition, since the inner carbon fiber web layer (A) forms a lot of fine pores in structure, it can smoothly communicate air, but does not cause decay by bacteria and has excellent biocompatibility, In addition, since it is softer than inorganic fibers, it is possible to apply exposure without any additional finishing material at the time of construction on the building, thereby greatly improving the convenience of the construction.

In the fifth step S5, the fiber orientation of the meta-aramid fiber web layer (A), the activated carbon fiber web layer (B), the glass fiber web layer (C), and the carbon fiber web layer (D) ), A carbon fiber web layer (D) is first placed on a conveying conveyor (50) for connecting the respective production lines forming each of the webs to one at a time, and a glass fiber web layer (C) The activated carbon fiber web layer (B) and the meta-aramid fiber web layer (A) are successively laminated and transported on the glass fiber web layer (C).

The sixth step S6 is a step of needle punching the multilayered web layers to form a multi-layer mat having a thickness of 10 to 30 mm and a density of 90 to 110 kg / m < 3 > do.

At this time, needle punching is performed to increase the binding force of the multi-layer web composed of the meta-aramid fiber web layer (A), the activated carbon fiber web layer (B), the glass fiber web layer (C), and the carbon fiber web layer , It is possible to firmly bind the web layer composed of multiple layers such that the fiber orientation properties are mutually alternated by using the secondary needle punching from the lower part to the upper part after the first needle punching.

In the seventh step S7, the multi-layered mat is continuously fed using at least two water-jet cutters 70 whose widths are adjustable so as to continuously cut both sides of the multi-layered mat so that the multi- Cut the both edges continuously in the longitudinal direction.

That is, it is preferable to use a water-jet cutter 70 when cutting both side edges of the multi-layered mat in the longitudinal direction for smooth cutting of the multi-layered mat with the meta-aramid web layer having excellent strength and elasticity formed thereon.

When the multi-layered mat is provided by a predetermined length with the integrating means for cutting the supply length of the multi-layered mat body, it is preferable that the multi-layered mat body can be cut by 50 to 100m using the widthwise cutter 701 Do.

In the eighth step S8, the multi-layered mat is passed into the dryer 80 having drying means for drying the moisture introduced into the fiber structure during the cutting of both side edges by the water jet cutter 70 .

The drying means may be applied to either the indirect drying method using hot air or the direct drying method using a drying roller depending on the thickness of the multi-layered mat, or both methods may be used in parallel.

In the ninth step (S9), in order to wind the cut multi-layer mat body in a roll form, a multi-layer mat roll having an end portion wound around the branch tube is placed on a winding roller, The multi-layer mat body is wound by rotating at a constant speed.

Meanwhile, the manufacturing apparatus for producing the glass fiber mat for construction of the present invention comprises a first line 10 in which carbon fibers are formed into a meta-aramid fiber web layer A having a thickness of 10 to 30 mm in a carding manner and continuously discharged; A second line 20 in which activated carbon fibers are formed by an air-laid method from an activated carbon fiber web layer (B) having a thickness of 20 to 40 mm and continuously discharged; A third line 30 in which glass fibers are formed in a glass fiber web layer (C) having a thickness of 100 to 150 mm by an airlaid method and continuously discharged; A fourth line 40 in which the carbon fibers are formed into a carbon fiber web layer D having a thickness of 10 to 20 mm in a carding manner and continuously discharged; The meta-aramid fiber web layer (A), the activated carbon fiber web layer (B), the glass fiber web layer (C), and the carbon fiber web layer (D) successively discharged from the first, second, third and fourth lines A conveying conveyor 50 for stacking and conveying at one time; A needle punching machine (60) configured by needle punching the multi-layered web layers conveyed by the conveying conveyor (50) to constitute a multi-layered mat having a mutual entangled thickness; A waterjet cutter (70) for continuously cutting both side edges of the needle punched multi-layered mat in the longitudinal direction to adjust the width and cutting the multi-layered mat to a predetermined length; A dryer (80) for drying the multi-layered mat with both side edges cut by the waterjet cutter (70); And a winding machine 90 for winding the dried multi-layer mat.

The first line 10 includes a first opener 101 for releasing the meta-aramid fibers continuously cut and cut to a predetermined length, and a second opener 101 for discharging meta-aramid fibers discharged from the first opener 101, A first mix tank 103 for storing meta-aramid fibers supplied through the first blow machine 102 and for mixing and discharging the meta-aramid fibers in a fixed amount; A first carding machine 104 for forming a meta-aramid fiber web A having a predetermined thickness by a carding method and continuously discharging meta-aramid fibers discharged in a predetermined quantity from the first carding machine 104, Aramid fibrous web layer (A) in a zigzag manner to adjust the fiber orientation and the thickness of the cross-lapping machine (105).

The second line 20 includes a second opener 201 for loosening activated carbon fibers continuously cut and cut to a predetermined length and a second opener 201 for discharging the activated carbon fibers discharged and discharged from the second opener 201 by wind A second mix tank 203 for storing the activated carbon fibers supplied through the second blow machine 202 and for mixing and discharging the activated carbon fibers in a fixed amount, And a second air-laid machine 204 which is formed of an activated carbon fiber web layer (B) having a predetermined thickness by an air flow method and continuously discharged.

The third line 30 includes a third opener 301 for loosening the glass fiber continuously cut and cut to a predetermined length and a third opener 301 for blowing the glass fiber discharged and discharged from the third opener 301 by wind A third mix tank 303 for storing and mixing the glass fibers supplied through the third blow machine 302 and the third blow machine 302 and discharging the glass fibers in a fixed amount, And a third air-laid machine 304 formed of a glass fiber web layer C having a predetermined thickness and continuously discharging the same.

The second and third air-laid machines are devices for continuously forming webs by transferring delicate fibers using a flow of air, and it is possible to arbitrarily adjust the fiber arrangement by adjusting the flow rate of air and the direction of spraying.

Further, in the air current supplying method using the air flow, it is preferable to use a method of sucking the fibers by the intake air, rather than a method of scattering the fibers by using the circulating air current.

The fourth line 40 includes a fourth opener 401 for loosening the carbon fiber continuously cut and cut to a predetermined length, a second opener 401 for feeding the carbon fibers discharged from the fourth opener 401 by wind, A fourth mix tank 403 for storing carbon fiber supplied through the fourth blow machine 402 and mixing and discharging the carbon fiber in a fixed amount, And a second carding machine 404 formed of a meta-aramid fiber web layer (A) having a predetermined thickness and continuously discharging the same.

The conveying conveyor 50 includes a meta-aramid fiber web layer A continuously discharged from the first and second carding machines, a carbon fiber web layer D, and an activated carbon fiber web layer continuously discharged from the second and third air- A single conveying conveyor 50 is formed long under the first, second, third and fourth lines so as to sequentially laminate the glass fiber web B and the glass fiber web layer C, (C), an activated carbon fiber web layer (B), and a meta-aramid fiber web layer (A) are successively laminated on the glass fiber web layer (C).

As described above, the meta-aramid fiber web layer A, the activated carbon fiber web layer B, the glass fiber web layer C, and the carbon fiber web layer D are sequentially laminated and transported to the single conveying conveyor 50 It is preferable that guide walls 501 having a predetermined height are provided on both sides of the conveying conveyor 50 in order to align the multi-layer web layers.

In addition, the first, second, third and fourth lines are provided with a detection sensor for monitoring whether or not the web layer is normally discharged in each line, so that when the web is not properly discharged from a specific line, It is desirable to prevent defects.

The needle punching machine 60 is formed by needle-punching a multi-layered web layer laminated and supplied by the conveying conveyor 50 to form a multi-layered mat having a thickness of 10 to 30 mm and a density of 90 to 110 kg / The needle punching was carried out under the conditions of a rotational speed of 200 to 600 rpm, a speed of 2 to 4 m / min and a taming degree of 40 to 60 times / cm with a needle of 4,500EA / m, It is desirable to improve the binding force of the multi-layered mat by punching the secondary needle from the lower part to the upper part.

The water jet cutter 70 includes at least two water jet cutters 70 capable of adjusting the width thereof. After needle punching is performed in the needle punching machine 60, the water jet cutter 70 continuously cuts both side edges of the continuously supplied multi- Thereby adjusting the length in the width direction of the multilayered mat.

Further, in the process of cutting both side edges of the multi-layered mat by using the water jet cutter 70 as described above, the integrated means for integrating the supplied lengths of the continuously supplied multi-layered mat in the needle punching machine 60 At the same time, it is preferable that the widthwise cutting knife 701 for cutting the multilayered mat body in the width direction is provided when the multilayered mat body is fed by a predetermined length.

The dryer 80 is provided with drying means for drying the moisture introduced into the fiber structure during the cutting of both side edges by the water jet cutter 70.

The drying means may include a plurality of hot air blowers installed at predetermined intervals on the upper and lower portions of the conveying section of the multi-layered mat to dry the multi-layered mat using hot air, or at least one pair of drying rollers capable of heating the surface temperature to a predetermined temperature The multi-layered mat is passed through the drying rollers to dry the multi-layered mat.

Depending on the thickness of the multi-layered mat, the drying means may be either an indirect drying method using hot air or a direct drying method using a drying roller, or both methods may be used in parallel.

In order to wind the cut multi-layer mat body in a roll form, the winding machine 90 is provided with a multi-layer mat roll in which a multi-layer mat body having both side edges continuously cut in the water jet cutter 70 is wound on a branch tube by a predetermined length A guide plate for holding both sides of the multilayered mat roll so that the multilayered mat roll wound around the winding roller can be rotated at a predetermined position, The multilayer mat can be wound by a predetermined length.

On the other hand, in order to compare the heat resistance with the glass fiber mats for construction manufactured through the method and apparatus for producing architectural glass fiber mat of the present invention, 100% glass fiber mat and 100% silica fiber mats sold on the market, The following prototype was produced.

≪ Example 1 >

The thickness of the meta-aramid fiber web layer (A) is 20 mm, the thickness of the activated carbon fiber web layer (B) is 20 mm, the thickness of the glass fiber web layer (C) is 150 mm and the thickness of the carbon fiber web layer 30 mm, and a density of 100 kg / m < 3 >.

≪ Example 2 >

A thickness of 30 mm for the meta-aramid fiber web layer (A), a thickness of 20 mm for the activated carbon fiber web layer (B), a thickness of 125 mm for the glass fiber web layer (C), and a thickness of 10 mm for the carbon fiber web layer 30 mm, and a density of 100 kg / m < 3 >.

≪ Example 3 >

The thickness of the meta-aramid fiber web layer (A) is 40 mm, the thickness of the activated carbon fiber web layer (B) is 20 mm, the thickness of the glass fiber web layer (C) is 100 mm and the thickness of the carbon fiber web layer 30 mm, and a density of 100 kg / m < 3 >.

<Test Example>

The thickness of the finished product of the glass fiber mat for construction of the present invention manufactured in the above-mentioned various examples was 30 5 mm, and the 100% glass fiber mat having the same thickness (30 5 mm) and the 100% And the results are shown in Table 1 below

Heating surface temperature (캜) Insulation surface temperature (℃) Example 1 Example 2 Example 3 Glass fiber mat Silica fiber mat 200 61 60 57 104 61 300 70 65 63 165 66 400 89 82 75 187 82 500 110 102 95 201 109 600 142 135 117 245 120 700 154 140 129 273 135 800 182 168 147 302 152 900 205 195 173 Dissolution 178 1000 219 205 189 Dissolution 192

As shown in the above Table 1, the glass fiber mat for construction of the present invention is superior to a general 100% glass fiber mat sold on the market. Compared with a 100% silica fiber mat, In the case of Example 3 in which the pre-punched thickness was 40 mm, it was proved that the heat-resistant property was superior to that of the 100% silica fiber mat to have an excellent effect of preventing flame spread when a fire occurred. Can be effectively applied as a built-in thermal insulating material for building because it has a remarkably improved moisture-proofing property and thus has an effect of preventing the aging phenomenon of glass fiber due to moisture absorption and heat and prolonging the service life of the heat insulating material.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention.

A: meta-aramid fiber web layer B: activated carbon fiber web layer
C: glass fiber web layer D: carbon fiber web layer
S1: first step S2: second step
S3: third step S4: fourth step
S5: fifth step S6: sixth step
S7: Seventh Step S8: Step 8
S9: Ninth step 10: First line
20: second line 30: third line
40: fourth line 50: conveying conveyor
60: Needle punching machine 70: Waterjet cutting machine
80: dryer 90: winding machine

Claims (16)

The meta-aramid fibers having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm are successively molded in a carding manner into a 10 to 30 mm-thick meta-aramid fiber web layer (A) simultaneously having both machine direction and cross direction fiber orientation A first step S1;
Activated carbon fibers having a fiber diameter of 7 to 15 占 퐉, a surface area of 1,100 to 1,600 m2 / g, and a fiber length of 40 to 80 mm were laminated in an air-laid manner to an activated carbon fiber web layer B);
A third step of successively molding glass fibers having a fiber diameter of 6 to 12 탆 and a fiber length of 40 to 100 mm in a glass fiber web layer (C) having a machine direction fiber bundle having a thickness of 100 to 150 mm S3);
A fourth step S4 of continuously forming carbon fibers having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm in a carding manner into a carbon fiber web layer D having a cross direction fiber orientation of 10 to 20 mm in thickness, ;
The fibers are sequentially stacked on the conveying conveyor 50 such that the fiber orientation properties of the meta-aramid fiber web layer A, the activated carbon fiber web layer B, the glass fiber web layer C and the carbon fiber web layer D are mutually interchanged, A fifth step S5;
A sixth step (S6) of needle-punching the multi-layered web layers to form a multi-layer mat having a thickness of 10 to 30 mm and a density of 90 to 110 kg / m &lt; 3 &gt;
A seventh step (S7) of cutting both sides of the multi-layered mat so that the multi-layered mat has a predetermined width;
An eighth step (S8) of drying the multi-layered mat with both edges cut off;
And a ninth step (S9) of winding the cut multi-layer mat in a roll form.
The method according to claim 1,
The meta-aramid fiber web layer (A) is supplied to a carding machine using meta-aramid fibers having a fiber diameter of 6 to 10 mu m and a fiber length of 40 to 80 mm to form a meta-aramid fiber web layer (A) having cross- The meta-aramid fiber web layer (A) is laminated in a zig-zag manner using a cross-rapping machine (105) and has a basis weight of 100 to 150 g / m 2 and a thickness of 20 to 40 mm, Wherein the meta-aramid fiber web layer (A) satisfies a temperature of 1,000 to 1,200 ° C.
The method according to claim 1,
The active carbon fiber web layer (B) is obtained by supplying activated carbon fibers having a fiber diameter of 7 to 15 탆, a surface area of 1,100 to 1,600 m 2 / g and a fiber length of 40 to 80 mm to an air- (B) having a thickness of 20 to 40 mm in a range of a basis weight of 50 to 100 g / m &lt; 2 &gt; at a speed of 1,500 rpm and a suction speed of 3,000 to 4,000 rpm.
The method according to claim 1,
The glass fiber web layer (C) was prepared by mixing E-glass long fiber yarn (YARN) having a fiber diameter of 6 to 12 탆 and a fiber length of 40 to 100 mm at a ratio of 5: 5, A glass fiber web layer (100 g / m &lt; 2 &gt;) having a thickness of 100 to 150 mm and a heat-resistant temperature of 400 to 650 deg. C at a cylinder speed of 500 to 600 rpm and a suction speed of 3,000 to 4,000 rpm C). &Lt; / RTI &gt;
The method according to claim 1,
The carbon fiber web layer (D) is obtained by supplying a carbon fiber having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm to a carding machine to produce a sheet having a thickness of 10 to 20 mm, And forming a carbon fiber web layer (D) satisfying a temperature of 800 to 1,200 占 폚.

The method according to claim 1,
Wherein the carbon fiber web layer (D) comprises carbon fiber having a fiber diameter of 6 to 10 탆 and a fiber length of 40 to 80 mm, a carbon fiber having a fiber diameter of 6 to 12 탆, a fiber length of 40 to 100 mm, Roving is mixed at a ratio of 7: 3 and fed to a carding machine to form a carbon fiber web layer (D) having a thickness of 10 to 20 mm and a heat resistance temperature of 800 to 1,200 ° C within a range of a basis weight of 80 to 120 g / Wherein the glass fiber mat is made of glass.
The method according to claim 1,
The carbon fiber web layer (D) comprises carbon fiber having a fiber diameter of 6 to 10 탆 and a length of 40 to 80 mm, E-glass fiber roving having a fiber diameter of 6 to 12 탆 and a length of 40 to 100 mm The mixture was fed to an air-laid machine at a cylinder speed of 1,200 to 1,500 rpm and a suction speed of 3,000 to 4,000 rpm to a basis weight of 80 to 120 g / Mm and a heat-resistant temperature of 800 to 1,200 ° C is formed on the surface of the carbon fiber web layer (D).
A first line 10 in which meta-aramid fibers having a fiber diameter of 6 to 10 mu m and a fiber length of 40 to 80 mm are formed in a carding manner into a meta-aramid fiber web layer A having a thickness of 10 to 30 mm and continuously discharged;
Activated carbon fibers having a fiber diameter of 7 to 15 占 퐉, a surface area of 1,100 to 1,600 m2 / g and a fiber length of 40 to 80 mm are formed by an air-laid method into an activated carbon fiber web layer (B) A second line (20) for discharging;
A third line 30 in which glass fibers having a fiber diameter of 6 to 12 占 퐉 and a fiber length of 40 to 100 mm are formed in a glass fiber web layer (C) having a thickness of 100 to 150 mm by an airlaid method and continuously discharged;
A fourth line 40 in which carbon fibers having a fiber diameter of 6 to 10 占 퐉 and a fiber length of 40 to 80 mm are formed in a carding web of a carbon fiber web layer D having a thickness of 10 to 20 mm and continuously discharged;
The meta-aramid fiber web layer (A), the activated carbon fiber web layer (B), the glass fiber web layer (C), and the carbon fiber web layer (D) successively discharged from the first, second, third and fourth lines A conveying conveyor 50 for stacking and conveying at one time;
A needle punching machine (60) configured by needle punching the multi-layered web layers conveyed by the conveying conveyor (50) to constitute a multi-layered mat having a mutual entangled thickness;
A waterjet cutter (70) for continuously cutting both side edges of the needle punched multi-layered mat in the longitudinal direction to adjust the width and cutting the multi-layered mat to a predetermined length;
A dryer (80) for drying the multi-layered mat with both side edges cut by the waterjet cutter (70);
And a winding machine (90) for winding the dried multi-layer mat.
9. The method of claim 8,
The first line 10 includes a first opener 101 for releasing meta-aramid fibers cut to a predetermined length and continuously supplied;
A first blow machine 102 for feeding the meta-aramid fibers discharged from the first opener 101 by using wind;
A first mix tank 103 for storing and mixing the meta-aramid fibers supplied through the first blow machine 102 and discharging meta-aramid fibers through a plurality of outlets;
A first carding machine 104 forming a meta-aramid fiber web layer A having a predetermined thickness by a carding method and continuously discharging meta-aramid fibers discharged in a predetermined amount from the first mix tank 103;
And a crossing machine (105) for continuously laminating the meta-aramid fiber web layer (A) continuously discharged from the first carding machine (104) in a zigzag manner.
9. The method of claim 8,
The second line (20) includes a second opener (201) for loosening activated carbon fibers continuously cut to a predetermined length and supplied continuously;
A second blow machine 202 for feeding the activated carbon fibers discharged from the second opener 201 by wind;
A second mix tank 203 for storing and simultaneously discharging the activated carbon fibers supplied through the second blow machine 202 in a fixed amount;
And a second air-laid machine (204) for continuously discharging the activated carbon fibers, which are discharged in a predetermined amount, from the activated carbon fiber web layer (B) having a predetermined thickness by using an air flow method.
9. The method of claim 8,
The third line (30) includes a third opener (301) for loosening the glass fibers continuously cut to a predetermined length and being supplied;
A third blow machine 302 for feeding the glass fiber discharged and discharged from the third opener 301 by wind;
A third mix tank 303 for storing and simultaneously discharging the glass fibers supplied through the third blowing machine 302 in a fixed amount;
And a third air laid machine (304) for forming a glass fiber web layer (C) having a predetermined thickness by using an air stream method and continuously discharging the glass fiber to be discharged in a constant amount. 9. The method of claim 8,
The fourth line (40) includes a fourth opener (401) for loosening carbon fibers continuously cut to a predetermined length and being supplied continuously;
A fourth blow machine 402 for feeding the carbon fibers discharged from the fourth opener 401 by using wind;
A fourth mix tank 403 for storing the carbon fibers supplied through the fourth blow machine 402 and for mixing and discharging the carbon fibers in a predetermined amount;
And a second carding machine (404) for forming carbon fiber webs (D) of a predetermined thickness by continuously discharging the carbon fibers discharged in a predetermined amount from the fourth mix tank (403) by a carding method. Apparatus for producing fiber mat.
9. The method of claim 8,
The conveying conveyor 50 includes a meta-aramid fiber web layer A, an activated carbon fiber web layer B, a glass fiber web layer C, Connecting the respective lines to form the web layer (D) in order;
And a guiding wall (501) having a predetermined height is formed on both sides of the web layer for aligning the web layer composed of multiple layers.
9. The method of claim 8,
The needle punching machine 60 is equipped with needles of 2,000 to 4,500EA / m, needle-punched at a rotation speed of 200 to 600 rpm, a speed of 2 to 4 m / min and a taming degree of 40 to 60 times / cm, Wherein the second needle punching is performed from the lower part to the upper part after the first needle punching to the lower part.
A glass fiber mat for construction, which is produced by the manufacturing method according to any one of claims 1 to 7.
A construction glass fiber mat produced by the manufacturing apparatus according to any one of claims 8 to 14.

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