JP2880933B2 - Method for producing inorganic fiber board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to the inner and outer walls of a building,
The present invention relates to a method of manufacturing an inorganic fiber board having excellent strength, which is used as a heat insulating sound absorbing material such as a partition, a door, a ceiling, or the like, or a core material of a panel.

[0002]

2. Description of the Related Art Conventionally, inner and outer walls of buildings, partitions,
Inorganic fiber boards are often used as heat insulating and sound absorbing materials for doors and ceilings, or as core materials for panels, and the like. Inorganic fiber boards are manufactured by binding inorganic fibers such as glass wool with a binder containing a thermosetting resin such as a phenol resin as a main component, and forming the board into a board shape. It is oriented substantially parallel to the plane direction.

However, such an inorganic fiber board is
Since the strength against compression in the direction perpendicular to the plane direction, that is, the thickness direction, is low, and the bending rigidity is low, there is a problem that it is easy to bend when it is made long.

In order to solve these problems, for example, Japanese Patent Publication No. 52-25644, Japanese Utility Model Publication No. 55-119826,
No. 59-88380, Japanese Utility Model Publication No. 60-146723, etc., have disclosed an inorganic fiber board in which inorganic fibers are oriented in a direction substantially perpendicular to the plane direction, or a panel on which a skin material is affixed using the core as a core material. It has been disclosed.

In these inorganic fiber boards or panels, after a general inorganic fiber board in which inorganic fibers are oriented substantially in parallel to the plane direction of the board, the inorganic fiber board is cut into a prism. The prismatic cut pieces are rearranged so that the orientation direction of the inorganic fibers is substantially perpendicular to the plane direction of the board to be obtained. Then, the prismatic cuts are bonded to each other with an adhesive to form a board, or the prismatic cuts are arranged on a skin material coated with an adhesive and formed into a board.

[0006]

However, as described above, in the method of preparing a general inorganic fiber board, cutting it into a prism and rearranging it, the cut material must be adhered and the board must be formed again. Therefore, there is a problem that the production of the board is troublesome and the cost is high.

Further, in the above method, there is a limit in the dimensional accuracy when the elastic inorganic fiber board is cut into a prismatic shape. There have been problems such as gaps being formed between objects, and irregularities being formed on the surface of a board obtained by arranging cut pieces, resulting in poor adhesion when a skin material such as a steel plate is attached.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for manufacturing an inorganic fiber board having excellent strength, in which inorganic fibers are oriented in a direction substantially perpendicular to a plane direction. It is another object of the present invention to provide a method of manufacturing an inorganic fiber board which can simplify the manufacturing process and reduce the manufacturing cost, has a smooth surface, has less variation in thickness, and has excellent peel strength when a skin material is bonded.

[0009]

In order to achieve the above object, a method of manufacturing an inorganic fiber board according to the present invention is a method of manufacturing an inorganic fiber board in which inorganic fibers are oriented in a direction substantially perpendicular to a plane direction. Depositing a resin binder on the inorganic fibers to form an inorganic fiber mat in which the inorganic fibers are oriented substantially parallel to the plane direction; and setting the inorganic fiber mat in a direction substantially perpendicular to the plane direction. And cutting the inorganic fiber mat, arranging the cut surface of the inorganic fiber mat in a plate shape in a direction in which the cut surface thereof is substantially parallel to the planar direction, and arranging the cut surface in a mold.
Heating and pressurizing the inorganic fiber mat to bind the inorganic fibers by heat melting or thermosetting of the resin binder, and forming the inorganic fiber mat into a board shape.

According to the present invention, an inorganic fiber mat formed by depositing an inorganic fiber while applying a resin binder thereto is cut at a predetermined width in a direction substantially perpendicular to a plane direction before heating and pressing. Since this cut material was arranged in a plate shape and arranged in a form so that the cut cross section became a direction substantially parallel to the plane direction, and heated and pressed so as to manufacture an inorganic fiber board, At the same time as the binding of the inorganic fibers by the resin binder, the cut pieces can be bonded together, and the process is simplified as compared with the conventional method, so that the manufacturing cost can be reduced.

[0011] Even if the dimensional accuracy of the cut material is not so high, since it is compression-molded to a predetermined thickness in the step of arranging in a mold and heating and pressing, the surface is smooth and thick. Thus, an inorganic fiber board can be obtained in which there is little variation and therefore no adhesion failure occurs when the skin material is adhered, and no gap is generated in the board.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, inorganic fibers are selected from ceramic fibers such as alumina fibers and mullite fibers in addition to glass fibers and mineral fibers.
A species or a mixture of two or more species by a method such as carding can be used. Among these, it is preferable to use glass wool, rock wool, or ceramic wool whose fibers are cotton-like because they are lightweight and have excellent heat insulation and sound absorbing properties. In addition, the inorganic fiber may be obtained by any method such as a centrifugal method and a flame method.
In addition, as long as the fire resistance and fire resistance are not impaired, organic fibers can be mixed and used in order to give flexibility to the inorganic fiber mat or the inorganic fiber board formed from the mat.

In the present invention, as the resin binder,
A thermoplastic resin binder or a thermosetting resin binder can be used. As the thermoplastic resin binder, it is preferable to use an emulsion such as vinyl acetate, vinyl chloride, or an acrylic resin, or a binder containing a water-soluble resin such as polyvinyl alcohol, methyl cellulose, carboxymethyl cellulose, or the like as a main component. Further, as the thermosetting resin binder, those containing phenol resin, melamine resin, urea resin, unsaturated polyester resin, epoxy resin, urethane resin or the like as a main component can be used. Of these, phenol resins, melamine resins, and urea resins are preferably used alone or as a mixture because of their excellent flame retardancy.

The amount of the resin binder applied to the inorganic fibers is preferably 1 to 50% by weight, based on the total weight of the inorganic fibers and the solid content of the resin binder, of the resin binder as a solid content. ~ 30% by weight is more preferred. When the applied amount of the resin binder is 1
If the amount is less than 50% by weight, the binding between the inorganic fibers is insufficient, and the strength of the inorganic fiber board becomes insufficient.
If the content is more than 10% by weight, the content of the flammable resin component becomes too large, and the fire resistance and fire resistance become insufficient.

In the present invention, the inorganic fiber mat is formed by depositing the inorganic fibers so as to be oriented substantially parallel to the plane direction while applying a resin binder to the inorganic fibers. The weight per unit area of the inorganic fiber mat is preferably 0.3 to 3 kg / m ² . When the weight per unit area is less than 0.3 kg / m ² , the weight per unit area tends to be non-uniform, and when it exceeds 3 kg / m ² , the handleability of the mat deteriorates.

The inorganic fiber board obtained by the production method of the present invention is preferably the density of 30 to 500 kg / m ^3, more preferably between 50~300 kg / m ^3. Density 30
If it is less than kg / m ^3, the compressive strength of the inorganic fiber board is not sufficient, 500 if more than kg / m ^3, the poor workability weight of inorganic fiber board is too heavy, economically Is also disadvantageous.

A preferred example of the method for producing an inorganic fiber board of the present invention will be described as follows.

First, while applying a resin binder to the inorganic fibers by a method such as a spraying method, the inorganic fibers are deposited on a conveyor moving at a constant speed to form an inorganic fiber mat in which the inorganic fibers are oriented substantially parallel to the plane direction. obtain. At this time, a desired density can be obtained by continuously pressing using a roll or the like without heating the inorganic fiber mat.

Next, as shown in FIG. 8, for example, the inorganic fiber mat 14 is cut at a predetermined width t using a slitter 23 having a rotary blade 24 in a direction substantially perpendicular to the plane direction thereof. The ribbon-shaped material 13 is used. The width t of the ribbon-like material 13 corresponds to the thickness of the inorganic fiber board to be manufactured. However, since the heating and pressing steps are performed later, there is no problem even if the thickness is slightly larger than the thickness of the inorganic fiber board. The thickness may be about 100 to 110% of the thickness of the board.

The method of cutting the inorganic fiber mat 14 at a predetermined width in a direction substantially perpendicular to the plane direction of the inorganic fiber mat 14 is performed continuously to the manufacturing process of the inorganic fiber mat 14 as described above. 9, the inorganic fiber mat 14 may be wound into a roll, and the roll 15 may be cut into a predetermined width t as shown in FIG. 14 may be folded in a zigzag shape and then cut at a predetermined width.

The ribbon-like material 13 of the inorganic fiber mat 14 obtained as described above is cut so that its cut surface is substantially parallel to the plane direction, that is, the ribbon-like material 1 at the time of cutting.
3 are arranged in a plate shape such that the width direction is the thickness direction of the formed inorganic fiber board, and is arranged in, for example, a metal mold. The method of arranging the ribbon-shaped objects 13 in a plate shape and arranging them in a mold is, as shown in FIG. 3, a method of arranging the ribbon-shaped objects 13 in a zigzag shape and arranging them in the mold 21. 5
As shown in (1), a method of arranging the ribbon-like materials 13 in a quail-like shape and arranging them in the mold 21 is preferably employed. At this time, the length of the ribbon-like material 13 is
If it is not long enough to be placed inside, it will be spliced as needed. Even if the ribbon-like material 13 is connected, it will be integrated by the resin binder when heated and pressed later, so that there is no problem such as peeling.

When the inorganic fiber mat 14 is wound up in a roll or folded in a zigzag shape and then cut, it is arranged in a plate shape only by making the cut surface substantially parallel to the plane direction. The form 2
1 may be arranged.

Subsequently, as shown in FIG. 4 or FIG.
The width of the mold 21 is reduced by the pressing means 21e to the size of the inorganic fiber board to be obtained. FIG. 4 or FIG.
Are formed on a pair of opposed sides 21a, 21a.
b is fixed to the width D of the inorganic fiber board to obtain, so that at least one of the other pair of sides 21c and 21d can be moved by the pressing means 21e.
The length is reduced to the length L of the inorganic fiber board to be obtained. Since the mold 21 also functions as a spacer at the time of pressure molding described later, its height is set to be the same as the thickness of the inorganic fiber board to be obtained. Also,
The shape of the mold 21 is not limited to that shown in FIG. 4 or FIG. 6, and it is sufficient that a movable portion for narrowing the inorganic fiber board is provided in at least one of the length direction and the width direction.

Next, as shown in FIG. 7, a heating device (not shown) comprising the ribbon-shaped material 13 arranged in the mold 21 and the mold 21 together, for example, an upper mold 22a and a lower mold 22b is provided. It is set in the press device 22, heated and pressed to perform press molding. At this time, the resin binder applied to the ribbon 13 is melted or hardened by heating and pressurizing, the inorganic fibers are bound together, and the ribbon 13 is integrated into a board shape. Therefore, even when the dimensional accuracy at the time of cutting the inorganic fiber mat 14 is not very good and the width of the ribbon-like material 13 varies, and the surface thereof has some irregularities when it is arranged in the form of a plate, the pressing is also performed. Smoothed during molding.

The heating temperature during press molding is set based on the melting or curing temperature of the resin binder. Also,
The heating device provided in the press device 22 can use a commonly used electric heater, but for the purpose of shortening the melting or curing time of the resin binder, for example, by using microwave heating, high-frequency heating or the like in combination. Alternatively, a mechanism may be used in which hot air is blown from the upper die 22a, the lower die 22b, and the like of the press device 22.

Prior to the press molding, one or both surfaces of the ribbon-like material 13 placed in the mold 21 in the planar direction may be provided.
When a skin material such as glass paper is arranged and then integrally molded by heating and pressing, the skin material can be simultaneously bonded by melting or curing of the resin binder, and the appearance of the inorganic fiber board can be improved. . In addition, a skin material such as a color steel plate may be attached to the obtained inorganic fiber board using an adhesive such as an epoxy resin to form a panel.

FIG. 1 shows an example of an inorganic fiber board 11 obtained by the manufacturing method of the present invention, and FIG. 2 is a partially enlarged view showing a portion surrounded by a circle in FIG. In the inorganic fiber board 11, the inorganic fibers 12 are oriented in a plane direction, that is, in a direction substantially perpendicular to the surface 11a of the inorganic fiber board 11, and the strength is excellent, and the surface 11a is smooth and poor adhesion of the skin material occurs. No, board thickness accuracy is high. In FIG. 1, a plurality of broken lines 11b, 11b,...
Is a bonding portion of the ribbon-like material 13 before heating and pressing, and is integrated when the heating and pressing are performed to form the inorganic fiber board 11.

[0028]

【Example】

Example An uncured resin binder containing a phenol resin as a main component was deposited on glass wool so as to have a weight per unit area of 1.7 kg / m ² while applying 9 wt% as a solid content. It was pressed by a roller in a heated state to obtain a glass wool mat having a thickness of about 2 cm and a density of about 80 kg / m ³ .

Next, this glass wool mat was cut using a slitter having a rotary blade so as to have a width within a range of 50 to 55 mm to obtain a ribbon-like material.

Subsequently, the obtained ribbon-shaped material is arranged in a zigzag shape as shown in FIG.
After being placed in the aluminum mold, the mold was narrowed to have a width of 900 mm and a length of 4000 mm.

After that, the ribbon-like material was set together with the mold in a press equipped with a heating device, pressed at 230 ° C. for 5 minutes to cure the resin binder, and the density was 100 kg / m ³ ,
A glass wool board having a width of 900 mm, a length of 4000 mm and a thickness of 50 mm was obtained.

In the obtained glass wool board, the glass wool was oriented in a direction substantially perpendicular to the plane direction, the surface was smooth, and there were no gaps or the like inside.

Comparative Example 1 An uncured resin binder containing a phenol resin as a main component was deposited on glass wool while applying 9% by weight as a solid content, and then heated and pressed to a density of 100 kg / m ³ . A glass wool board was obtained.

Next, the obtained glass wool board is
Using a panel cutting machine, the sheet was cut to a set width of 50 mm to obtain a prismatic cut material. The accuracy of the width of the obtained cut material is 50 ± 4
mm, the variation was large.

Subsequently, the cut materials are rearranged and arranged in a plate shape so that the width direction of the obtained cut material is the thickness direction of the board after molding, and an epoxy resin-based material is applied to the contact surfaces between the cut materials. the adhesive 300 g / m ² coated with adhesive, width 900 mm, length 40
A glass wool board having a thickness of 00 mm and a thickness of 50 mm was obtained.

The glass wool board thus obtained is
Although the glass wool was oriented in a direction substantially perpendicular to the plane direction, the surface had irregularities.

Comparative Example 2 An uncured resin binder containing a phenol resin as a main component was deposited on glass wool while applying 9 wt% as a solid content, and then heated and pressed to obtain a density of 100 kg / m ³ , A general glass wool board having a thickness of 50 mm was obtained.

Test Examples 10 cm square samples were cut out from the glass wool boards of the above Examples and Comparative Examples 1 and 2, and the compressive strength in the thickness direction of the samples was measured. The compression strength (10% compression) was measured using a compression tester "Strograph-W2".
(Trade name, manufactured by Toyo Seiki Co., Ltd., head speed 5 mm / min).

An epoxy resin adhesive was applied to both sides of the glass wool board obtained in Example and Comparative Example 1.
A 0.4 mm thick colored steel sheet coated with g / m ² was laminated and pressed to form a sandwich panel.

The thickness of each of the obtained sandwich panels was randomly measured at 30 places to evaluate the accuracy of the thickness.

Further, ten samples of 10 cm square were randomly cut out from each sandwich panel, and the peel strength between the glass wool board and the color steel plate was measured for each of them, and the degree of variation in the peel strength was evaluated. The peel strength was measured at a tensile speed of 10 mm / min while fixing the sample between upper and lower jigs of a tensile tester.
Table 1 shows the results.

[0042]

[Table 1]

From the results in Table 1, it can be seen that the boards of Examples and Comparative Example 1, that is, the boards in which the glass wool is oriented in a direction substantially perpendicular to the plane direction, have the glass wool oriented substantially parallel to the board plane direction. It can be seen that the compressive strength is higher than that of the board of Comparative Example 2 which is a general conventional product.

Further, the glass wool board of the embodiment has a very high thickness accuracy when used as a sandwich panel and has a higher peel strength between the glass wool board and the color steel plate than that of the comparative example 1, that is, It can be seen that the surface of the glass wool board was smooth and the skin material was sufficiently bonded.

[0045]

As described above, according to the method for manufacturing an inorganic fiber board of the present invention, an inorganic fiber mat containing a resin binder is cut at a predetermined width before being molded by heating and pressing. By rearranging and arranging the direction of the inorganic fiber so as to be almost perpendicular to the plane of the board, and by applying heat and pressure in this state, the cut material is bonded at the same time as the board is formed, so the direction of the inorganic fiber is changed. The process is simplified and the manufacturing cost can be reduced as compared with the conventional method of manufacturing an inorganic fiber board which is substantially perpendicular to the plane.

In addition, even if the dimensional accuracy at the time of cutting the inorganic fiber mat is low, the surface becomes smooth when the board is formed by heating and pressing, so that there are few irregularities on the surface, the thickness variation is small, Accordingly, an inorganic fiber board having excellent strength can be manufactured because the peel strength is excellent when the skin material is stuck and the inorganic fibers are oriented in a direction substantially perpendicular to the plane direction.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of an inorganic fiber board manufactured by a method for manufacturing an inorganic fiber board of the present invention.

FIG. 2 is a partially enlarged perspective view showing a portion surrounded by a circle in FIG. 1;

FIG. 3 is a diagram illustrating a process of manufacturing the inorganic fiber board according to the embodiment.
It is a top view which shows the state which arranged the ribbon-shaped thing in the mold.

FIG. 4 is a diagram illustrating a process of manufacturing the inorganic fiber board according to the embodiment.
It is a top view showing the state where a mold was narrowed after a ribbon-like thing was arranged in a mold.

FIG. 5 is a plan view showing a state in which a ribbon-like material is arranged in a mold in another embodiment of the method of manufacturing an inorganic fiber board of the present invention.

FIG. 6 is a plan view showing a state in which the ribbon is placed in the mold and then the mold is narrowed in the embodiment.

FIG. 7 is a partially omitted side view showing a method for press-molding a ribbon-shaped material arranged in a mold in one embodiment of the method for producing an inorganic fiber board of the present invention.

FIG. 8 is a partially omitted perspective view showing a method for cutting an inorganic fiber mat in one embodiment of the method for manufacturing an inorganic fiber board of the present invention.

FIG. 9 is a perspective view showing a method for cutting an inorganic fiber mat in another embodiment of the method for manufacturing an inorganic fiber board of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Inorganic fiber board 12 Inorganic fiber 13 Ribbon 14 Inorganic fiber mat 15 Roll of inorganic fiber mat 21 Form 22 Press device 23 Slitter 24 Rotary blade

Continuation of front page (58) Field surveyed (Int.Cl. ⁶ , DB name) B32B 1/00-35/00 E04B 1/80

Claims (6)

(57) [Claims] 1. A method of manufacturing an inorganic fiber board in which inorganic fibers are oriented in a direction substantially perpendicular to a plane direction, wherein the inorganic fibers are deposited while applying a resin binder to the inorganic fibers so that the inorganic fibers are substantially parallel to the plane direction. A step of forming an oriented inorganic fiber mat, a step of cutting the inorganic fiber mat at a predetermined width in a direction substantially perpendicular to a plane direction of the inorganic fiber mat, and a cut surface of the cut material of the inorganic fiber mat. A step of arranging them in a plate shape in a direction substantially parallel to the direction and arranging them in a mold, heating and pressing the inorganic fiber mat, and bonding the inorganic fibers by heat melting or thermosetting of the resin binder. And forming the board into a board shape. 2. The inorganic fiber mat is cut at a predetermined width in a direction substantially perpendicular to a plane direction of the inorganic fiber mat into a ribbon-like material, and the ribbon-like material is oriented so that its cut surface is substantially parallel to the plane direction. The method for producing an inorganic fiber board according to claim 1, wherein the inorganic fiber board is arranged in a plate shape and arranged in the mold. 3. The method for producing an inorganic fiber board according to claim 2, wherein the ribbon-like materials are arranged in a zigzag or quail-like shape and arranged in the mold. 4. A method according to claim 1, wherein the inorganic fiber mat is wound into a roll, the roll is cut into a predetermined width, and the cut is oriented such that a cut surface is substantially parallel to a plane direction. The method for producing an inorganic fiber board according to claim 1, wherein the inorganic fiber board is disposed in the inside. 5. The method for producing an inorganic fiber board according to claim 1, wherein a thermoplastic resin binder or an uncured thermosetting resin binder is used as the resin binder. 6. The cutting width of the inorganic fiber mat is set to 100 to 11 with respect to the thickness of the inorganic fiber board to be manufactured.
The method for producing an inorganic fiber board according to any one of claims 1 to 5, wherein the content is 0%.