JP2001347584A - Heat insulating fiberboard and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a woody fiberboard having excellent heat insulating properties. SOLUTION: A raw material mixture R including natural organic fibers and a thermoplastic resin is charged in the cells 10A of a honeycomb structure 10 and heated by hot air to uniformly melt the honeycomb structure up to the core part of the honeycomb structure to bond the fibers to manufacture the low density fiberboard having good heat insulating properties.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat insulating fiberboard mainly useful as a heat insulating material for buildings and a method for producing the same.

[0002]

2. Description of the Related Art As a conventional heat insulating material, a sheet of inorganic fiber such as glass wool or rock wool, or a plate of synthetic resin foam such as polyurethane foam or polystyrene foam has been used.

[0003]

However, heat insulating materials made of these materials have no decay property, cannot be incinerated in the case of inorganic fiber sheets, and small pieces are scattered to contaminate the working environment. The body can be incinerated, but the polyurethane foam will emit toxic gases when incinerated, and the polystyrene foam will emit black smoke when incinerated, all of which cause significant air pollution. . Insulating fiberboard in which natural organic fibers are bound by a thermoplastic resin has been conventionally provided, but such an insulative fiberboard is manufactured by heat compression molding or extrusion and is not low density. It is not suitable as a heat insulator.

[0004]

According to the present invention, as a means for solving the above-mentioned conventional problems, a raw material mixture containing natural organic fibers and a thermoplastic resin in all sections (10A) of a honeycomb structure (10). R is filled and heated to melt the thermoplastic resin and bind the natural organic fibers to the heat-insulating fiberboard A or to some of the compartments (10A) of the honeycomb structure (10). A raw material mixture R containing fibers and a thermoplastic resin was filled, heated to melt the thermoplastic resin and bind the natural organic fibers, and the other section (10A) was filled with an adsorbent K. A heat insulating fiberboard B is provided. It is desirable that a moisture-proof sheet is adhered to the front and / or back surfaces of the heat insulating fiber boards A and B. The heat insulating fiberboard A
As a preferable method for producing the honeycomb structure (10), a honeycomb structure (10) is placed on a net (2), and a raw material mixture R containing natural organic fibers and a thermoplastic resin is sprayed thereon. The raw material mixture R is filled in all the compartments (10A) of (10), and hot air is passed from above or below without applying or adhering the net (2) from above, and the raw material mixture R in the raw material mixture R is filled. There is a method of binding the natural organic fibers by melting a thermoplastic resin, and a preferable method of manufacturing the heat insulating fiberboard B is to place a honeycomb structure (10) on a net (2), By spraying a raw material mixture R containing natural organic fibers and a thermoplastic resin in a state where some of the compartments (10A) are masked from above, the honeycomb structure
The unmasked section (10A) of (10) is filled with the raw material mixture R, and the section (10A) filled with the raw material mixture R is further filled.
A) is masked, and the adsorbent K is sprayed thereon to form a section (1) where the raw material mixture R of the honeycomb structure (10) is not filled.
0A) is filled with the adsorbent K, and hot air is blown from above or below without adhering or adhering the net (2) from above to melt the thermoplastic resin in the raw material mixture R. There is a method of binding the natural organic fibers.

[0005]

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described in detail below. [Natural Organic Fiber] The main natural organic fiber used in the present invention is wood fiber. The wood fiber is preferably produced by steaming a wood chip and then defibrating with a defibrating machine.Instead of the wood chip, a hard board, an insulation board, and a chip of a wood board such as plywood are pulverized into chips. After steaming, desirably, it may be defibrated by a defibrating machine. Desirable wood fiber size is in the range of diameter 0.1 to 2.0 mm, length 5 to 50 mm, average diameter 0.5 mm, average length 30 mm
belongs to. In addition to the above-mentioned wood fibers, in the present invention, natural organic fibers such as bamboo fibers, hemp fibers, cotton, coconut palms, bacas, firgrass and rice straw may be used. The natural organic fibers may be used in combination of two or more.

[Thermoplastic resin] Examples of the thermoplastic resin used in the present invention include vinyl acetate resin, SBR, acrylic resin, styrene acrylic resin and the like. Desirable thermoplastic resins include polyolefins such as polyethylene and polypropylene. Since polyolefin is composed of only carbon and hydrogen, it is harmless to the human body,
No harmful gas is generated even by incineration. The thermoplastic resin is preferably in the form of powder, fibrous, or emulsion. When the thermoplastic resin is powder, regenerated powder obtained by crushing a molded article of synthetic resin or scrap of fiber is used. A product or a fibrous regenerated product obtained by melt-spinning the scrap can also be used.

[Raw material mixture] The natural organic fiber and the thermoplastic resin are usually from 8: 2 to 6: 4 as solids to solids.
Mix in weight ratio. In addition to the above components, for example, a water repellent such as paraffin wax, polyethylene wax, silicone oil, or a flame retardant such as a phosphorus-nitrogen flame retardant or a boric acid flame retardant may be added.

[Production of Insulating Fiberboard] FIG. 1 shows an example of an apparatus suitable for producing the insulating fiberboard of the present invention. FIG.
In (1), a tank body is divided into an upper part (1A) and a lower part (1B), and a release-treated net (2) is stretched over the upper end of the lower part (1B). . The above net (2) is usually 20
１００100 mesh is used. A hot air blowing duct (3) is opened at the upper end of the upper part (1A) .The duct (3) has a hot air producing device (not shown) and a cold air supply duct (5) through a three-way valve (4) and a valve. (7) Via raw material supply hopper
(6) and are connected. On the other hand, a suction path (8) with a valve (9) is connected to the lower end of the lower part (1B).

In the above apparatus, a honeycomb structure (10) as shown in FIG. 2 is placed on a net (2). The honeycomb structure (10) is made of paper, wood, plastic, light metal or the like. The inside of the tank (1) is sucked by the suction path (8), and the material mixture R is sucked from the hopper (6) into the tank (1) by opening the valve (7), and the honeycomb on the net (2) is opened. Structure (1
The raw material mixture R is filled in each section (10A) of (0). Next, the valve (7) of the hopper (6) is closed, and the hot air blowing duct (3) is opened by the three-way valve (4) to blow hot air into the tank body (1). The temperature of the hot air is set to a temperature equal to or higher than the melting point of the thermoplastic resin contained in the raw material mixture R, and the raw material mixture R filled in each section (10A) by melting the thermoplastic resin.
Bind the natural organic fibers inside. In this case, since the tank body (1) is sucked from the lower end by the suction path (8), the hot air smoothly flows through the raw material mixture R filled in each section (10A) of the honeycomb structure (10). The thermoplastic resin inside the raw material mixture R is uniformly melted and uniformly binds the natural organic fibers. Then, connect the cool air supply duct (5) to the hot air blow duct (3) by the three-way valve (4), and
(1) The cold air is sucked into the inside to cool the raw material mixture R of the honeycomb structure (10). In this way, the heat insulating fiberboard A of the present invention is manufactured, and the fiberboard A is placed on the upper portion (1A) of the tank body (1).
And the lower part (1B) is separated from the tank body (1).

According to the present invention, as shown in FIG. 3, the raw material mixture R is partially contained in the section (10A) of the honeycomb structure (10).
May be filled with the adsorbent K. Examples of the adsorbent K include activated carbon, silica gel, zeolite, artificial zeolite, and diatomaceous earth.

In order to manufacture such a fiber board, as shown in FIGS. 4 and 5, on a honeycomb structure (10), there is provided a net having meshes corresponding to the honeycomb shape of the honeycomb structure (10). (2A), which is obtained by applying a mask (2B) to a predetermined portion of the net (2A), and then spraying the raw material mixture R. Then, the raw material mixture R is not filled in the section (10A) of the honeycomb structure (10) to which the masking (2B) has been applied.

After spraying the raw material, the net (2A) was removed, and this time, as shown in FIG. 6, the honeycomb shape of the honeycomb structure (10) coincided with the portion corresponding to the masking (2B) of the net (2A). The masking sheet (2C) provided with the shaped hole (2D) is applied and the adsorbent K is sprayed. After spraying the adsorbent K, the raw material mixture R of the honeycomb structure (10) is blown by blowing hot air in the same manner as in the previous example.
Melts the thermoplastic resin in the raw material mixture R of the section (10A) in which the fibers are filled to bind the fibers.

[0013] The fiberboard B thus manufactured has a deodorizing function, a function of absorbing and discharging moisture, and the like, because the adsorbent K is filled in various sections (10A) of the honeycomb structure (10). .

In the fiber board B, in order to sufficiently exhibit the functionality of the adsorbent K, the partition (10) of the honeycomb structure (10) is required.
It is desirable that the section (A) filled with the adsorbent K in (A) occupies 10 to 50% of the whole section.

In the above case, the adsorbent K is filled before the hot air is passed through the honeycomb structure (10). However, in the present invention, the adsorbent K is cooled before or after the hot air is passed through the honeycomb structure (10).
May be filled. In this case, the masking sheet
(2C) does not need to be used.

FIG. 7 shows another example of the apparatus used in the present invention. In FIG. 7, (11) is a tank body, and the upper part (11A)
And a lower part (11B), a release-treated net (12) is stretched at the upper end of the lower part (11B), and a valve (14) is provided at the upper end of the upper part (11A). (1)
3) is connected, and a valve (16) is connected to the suction air passage (13).
Is connected to the raw material supply hopper (15). The lower part
(11B) Lower end of hot air blow duct with valve at bottom (17)
The cold air supply duct (18) is connected to the duct (17) via a three-way valve (19).

In the above apparatus, the honeycomb structure (10) is placed on the net (12), and the valves (14) and (16) are opened to blow air from the suction air passage (13) into the tank (11). The raw material mixture R is supplied from the hopper (15) into the tank body (11) to fill each section (10A) of the honeycomb structure (10) on the net (12) with the raw material mixture R. Next, after releasing the release net (12A) on the honeycomb structure (10), the suction air passage
(13) Therefore, the inside of the tank (11) is sucked and the hot air blowing duct (1
Hot air is blown from 7) into the tank body (11), and the hot air is blown into the raw material mixture R filled in each section (10A) of the honeycomb structure (10).
To melt the thermoplastic resin in the raw material mixture R to bind the fibers. In this case, as in the previous example, the hot air passes through the raw material mixture R filled in each section (10A) of the honeycomb structure (10) and uniformly melts the thermoplastic resin in the raw material mixture R. When the hot air passes through the raw material mixture R from bottom to top, the honeycomb structure (10)
There is an advantage that the raw material mixture R in each section (10A) is uniformly dispersed.

Next, a cool air supply duct (18) is connected to a hot air blow duct (17) by a three-way valve (19), and a suction air passage (1) is connected.
While the inside of the tank body (11) is sucked by 3), cool air is supplied into the tank body (11) to cool the raw material mixture R to produce an insulating fiberboard. (11) Upper part (11A) and lower part (11
B). As described above, in the present invention, since the raw material mixture R filled in each section (10A) of the honeycomb structure (10) is formed without pressing, the obtained fiber board can have a low density.

[Lamination of Sheet] A moisture-proof paper or a plastic sheet such as a polypropylene sheet, a polyethylene sheet, or a polyester sheet may be adhered as a moisture-proof sheet to one or both surfaces of the heat insulating fiber board of the present invention. Usually, the above-mentioned sheet is attached to one or both sides of the heat-insulating fiberboard with an adhesive after the production thereof, or by heat-sealing with high frequency, electromagnetic waves or the like. By attaching the moisture-proof sheet to the heat-insulating fiberboard in advance as described above, it is possible to save time and effort for attaching the moisture-proof sheet on site.

Although the above two devices are both batch type devices, the present invention also employs a continuous type device illustrated in FIG. This apparatus will be described below.
Is accumulated in a hopper (21), and is formed from a supply roll (22) through a forming box (23) in which a mesh (24) is stretched at a bottom portion.A honeycomb structure (20) and a net ( 26A) is spread on a forming net conveyor (27) on which the raw material mixture R is filled into the unmasked section of the honeycomb structure (20) by the net (26A), and the mat M is formed. Is done.
Next, the mat M is a forming net conveyor (27).
And a masking sheet (26B) obtained by masking a section filled with the raw material mixture R on the mat M, and the adsorbent K is sprayed from the nozzle (25). The adsorbent K is filled in a section of the mat M not filled with the raw material mixture. Next, the mat M is connected to the upper net conveyor (29) and the lower net conveyor (3).
0), and is heated by hot air by the heating chamber (31). A plurality of hot air blowing ports (32A) to which a hot air supply path (32) is connected are arranged below the heating chamber (31), and a suction port (33A) to which a suction path (33) is connected is installed above. A plurality of hot air blown from the hot air blowing port (32A) are passed through the mat M, melt the thermoplastic resin in the mat M, and are sucked through the suction port (33A). ). In this way, the mat M is pressed by the upper and lower net conveyors (29, 30), and the wood fibers in the mat M are bound by the molten thermoplastic resin, transferred to the transport conveyor (35) and cooled. The cooling air is blown by the fan (34) to be cooled, and the original wood fiberboard M 'is obtained.

An adhesive S is spray-applied to the surface of the original plate M 'from a nozzle (36), and a moisture-proof sheet (37A) drawn from a roll (37) is pressed thereon by press rolls (38A, 38B). Then, the moisture-proof sheet (37A) in a state of being passed between the original sheets M 'by the cutter (39) is cut into the heat insulating fiberboard B.

When the heat insulating fiberboard A is manufactured, the raw material mixture R may be sprayed on a forming net conveyor (27) on which the honeycomb structure (20) is mounted, and the mat M may be formed. It is not necessary to use a net (26A) in which some sections are masked and a masking sheet (26B) in which the sections filled with the raw material mixture R are masked as in B.

The heat-insulating building boards A and B of the present invention are arranged, for example, outside the wall frame pillar (41) as shown in FIG. Is applied to the wall structure to be stretched, or as shown in FIG.
The present invention is applied to a floor structure or the like in which a floor material (55) or a floor base material is laid on a floor foundation (51) composed of a floor material (53) and a joist (54).

Example 1 A raw material mixture R having the composition shown in Table 1 was prepared, and a net (2) (# 100) was arranged below the honeycomb structure (10) as shown in FIG. The raw material mixture R is blown into each section (10) of the honeycomb structure (10).
A), and then hot air at 190 ° C. was blown from above to melt the thermoplastic resin and fuse the fibers and fibers with the honeycomb structure (10). Thereafter, the honeycomb structure (10) was taken out by cooling, and moistureproof paper was stuck on the upper and lower sides with a vinyl acetate adhesive to obtain a heat insulating fiberboard A.

Example 2 A raw material mixture R having the composition shown in Table 1 was prepared, and a net (12) (# 100) was placed below the honeycomb structure (10) as shown in FIG. The raw material mixture R is blown into each section (10) of the honeycomb structure (10).
A), then a net (12A) (# 100) is also placed on the upper part of the honeycomb structure (10), and 190 ° C. from the lower part.
The hot air is blown back, the thermoplastic resin is melted, the fibers and the fibers are fused with the honeycomb structure (10), and then cooled by blowing cool air from the top, and then taken out. A heat insulating fiberboard A was obtained by sticking with an adhesive.

Example 3 A raw material mixture R was prepared in the same manner as in Example 1, and the net (2) (# 100) was placed below the honeycomb structure (10). 4), a net (2A) as shown in FIG. 4 was arranged, and the raw material mixture R was blown from above to fill the unmasked section (10A) of the honeycomb structure (10). Thereafter, hot air of 190 ° C. was blown from the upper portion, and the honeycomb structure (10)
After the thermoplastic resin in the raw material mixture R filled in the unmasked section (10A) is melted to fuse the fibers and the fibers to the honeycomb structure (10), as shown in FIG. So that the masking sheet (2C)
It was placed above (10) and activated carbon was blown from above. As a result, a heat insulating fiberboard B in which activated carbon was filled in 18% of the sections (10A) of the honeycomb structure (10) was obtained.

Example 4 A raw material mixture R having the composition shown in Table 1 was prepared and produced in the same manner as in Example 1,
Core insulation was obtained.

Example 5 A raw material mixture R having the composition shown in Table 1 was prepared and manufactured in the same manner as in Example 1 to produce a heat insulating fiberboard A.
Core insulation was obtained.

[Comparative Example 1] The raw material mixture of Example 1 was sprayed on a template to form a mat.
Hot pressing was performed at a temperature of 0 ° C. and a pressure of 3 kg / cm ² for 5 minutes to produce a wood fiber board. Table 1 shows the measurement results of the physical properties of the heat insulating fiberboard and the wood fiberboard sample.

[0030]

[Table 1]

According to Table 1, the samples of Examples 1 to 5 were uniformly mixed with the thermoplastic resin by passing hot air through the raw material mixture R filled in the section (10A) of the honeycomb structure (10). Melts and binds the fibers. In addition, a low-density plate can be obtained without pressing. As a result, a plate having excellent heat insulating properties (low thermal conductivity) and strength can be obtained. On the other hand, the wood fiber board obtained by hot pressing has difficulty in melting the thermoplastic resin at the core, and it is difficult to obtain a board of low density. The resulting wood fiber board is inferior in heat insulation and strength.

[0032]

According to the present invention, a heat-insulating fiberboard excellent in heat-insulating properties and having high strength and suitable as a heat-insulating material for buildings can be obtained. Also, since it has a built-in honeycomb structure, it has excellent compression resistance.

[Brief description of the drawings]

FIG. 1 is an explanatory view of one embodiment of an apparatus used in the present invention.

FIG. 2 is a perspective view of a honeycomb structure.

FIG. 3 is a perspective view of a honeycomb structure partially filled with an adsorbent.

FIG. 4 is a perspective view of a honeycomb structure with a masking net attached.

FIG. 5 is an explanatory view of a device into which a honeycomb structure is inserted.

FIG. 6 is a perspective view of a honeycomb structure with a masking sheet attached.

FIG. 7 is an explanatory view of another embodiment of the device used in the present invention.

FIG. 8 is an explanatory view of still another embodiment of the device used in the present invention.

FIG. 9 is an explanatory diagram when applied to a wall.

FIG. 10 is an explanatory diagram when applied to a floor.

[Explanation of Signs] 2 Net 10, 20 Honeycomb structure 10A Section A, B Heat insulating fiberboard K Adsorbent R Raw material mixture

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29K 105: 12 B29L 9:00 B29L 9:00 31:10 31:10 B29C 67/12 F-term (reference) 2E001 DB01 DD01 GA07 GA24 GA87 HB01 HC01 HC05 HC07 HC11 HD11 JA06 JC01 JC05 JC06 JC07 JC08 JD02 4F100 AJ01A AK01A AK22G BA01 BA02 BA44 CB00 DC02A DG01A DG03 DG10 EC03A EC032 AJ42 J04 E42E04 E04 E12E12 E12 E12 E12 E12 E12 AD07 AG03 AH46 HA10 HA29 HA34 HA36 HA40 HB01 HB12 HC12 HF30 HK21

Claims (5)

[Claims] A raw material mixture containing natural organic fibers and a thermoplastic resin is filled in all the sections of the honeycomb structure, and the thermoplastic resin is melted by heating to bind the natural organic fibers. Insulating fiberboard characterized by the following 2. A part of the honeycomb structure is filled with a raw material mixture containing a natural organic fiber and a thermoplastic resin, and heated to melt the thermoplastic resin to bind the natural organic fiber. Characterized in that the other compartments are filled with an adsorbent material 3. The heat-insulating fiberboard according to claim 1, wherein a moisture-proof sheet is adhered to a front surface and / or a back surface of the heat-insulating fiberboard. 4. A honeycomb structure is placed on a net, and a raw material mixture containing natural organic fibers and a thermoplastic resin is sprinkled on the honeycomb structure to fill the entire space of the honeycomb structure with the raw material mixture. Then, hot air is passed from above or below without adhering or adhering a net from above to melt the thermoplastic resin in the raw material mixture and bind the natural organic fibers. The method for producing a heat insulating fiberboard according to claim 1. 5. A honeycomb structured body is placed on a net, and a raw material mixture containing natural organic fibers and a thermoplastic resin is sprayed in a state in which a part of the honeycomb structured body is masked from above. An unmasked section is filled with the raw material mixture, the section filled with the raw material mixture is further masked, and an adsorbent is sprayed thereon. Filling, by passing hot air from above or below without applying or adhering a net from above to melt the thermoplastic resin in the raw material mixture and bind the natural organic fibers. The method for producing a heat-insulating fiberboard according to claim 2.