JP3244002B2 - Rock wool board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a rock wool board, and more specifically, to an exterior material, an interior material, an interior base material, an eaves ceiling material, a bus wall material, a bus ceiling material, and a floor material. The present invention relates to a method for producing a rock wool board useful to be used as a wool board.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a rock wool board, for example, after a sheet is formed into a plate shape by a wet method,
It has been known to obtain a rock wool board by drying.

The thus obtained rock wool board has good heat insulating properties and sound absorbing properties, and has been used as a wall material or a ceiling material of a building that requires strong heat insulating properties and sound absorbing properties. .

[0004]

However, in such a method for manufacturing a rock wool board, since the obtained rock wool board itself is a fibrous inorganic fiber, it easily absorbs water, and Exterior materials, interior materials, interior base materials, eaves ceiling materials, bus wall materials, bus ceiling materials, floor materials that have low surface hardness and, as a result, require high surface hardness and water resistance As a result, it cannot be generally used.

The present invention has been made in order to eliminate the above-mentioned disadvantages, and an object of the present invention is to increase surface hardness and water resistance. It is an object of the present invention to provide a method for manufacturing a rock wool board that can be used as a material, an eaves ceiling material, a bus wall material, a bus ceiling material, and a floor material.

[0006]

According to a first aspect of the present invention, there is provided a method for manufacturing a rock wool board, wherein the entire rock wool base material which has been formed into a plate shape by a wet method and dried is impregnated with a thermosetting resin liquid. Thereafter, the thermosetting resin is dried to cure the thermosetting resin so that the impregnation rate of the same thermosetting resin liquid on the exposed surface of the rock wool base material is increased.

In the method for manufacturing a rock wool board according to a second aspect of the present invention, the concentration of the thermosetting resin liquid is 1 wt.
% Or more and 30 wt% or less.

In a third aspect of the present invention, the method for manufacturing a rock wool board is characterized in that the impregnation is performed until the thermosetting resin liquid permeates the entire rock wool substrate.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described in detail.

FIG. 1 is a schematic view showing a rock wool board obtained by a method for manufacturing a rock wool board according to one embodiment of the present invention. FIG. 2 is a graph showing a change in the resin impregnation rate in each step in the method for manufacturing a rock wool board according to one embodiment of the present invention. FIG. 3 is a graph showing a change in water content of each step in the method for manufacturing a rock wool board according to one embodiment of the present invention.

The method for producing a rock wool board according to the present invention comprises the steps of: impregnating the whole of a rock wool substrate which has been formed into a plate shape by a wet process and dried with a thermosetting resin liquid; The thermosetting resin is dried to cure the thermosetting resin so as to increase the impregnation rate of the thermosetting resin liquid.

The rock wool base material is formed into a sheet by a wet method and dried. The method of paper-making into a plate shape by this wet method is the same as the paper-making method used when paper-making a rock wool sound-absorbing plate.

The above-mentioned rock wool is mainly made of basalt, diorite, or slag, and is blown away by a centrifugal force, compressed air, high-pressure steam, or the like, melted in an electric furnace or a blast furnace. It is an inorganic fiber that has been quenched and fiberized.

The thermosetting resin liquid impregnates the entire rock wool substrate, and is, for example, filled in an impregnation tank or the like. Examples of the thermosetting resin liquid include phenol resins, melamine resins, epoxy resins, urethane resins, unsaturated polyester resins, urea resins, and the like.

The impregnation may be performed by immersing the entire rock wool substrate in the thermosetting resin liquid, as long as the entire rock wool substrate can be impregnated. The above-mentioned thermosetting resin liquid may be partially injected from an appropriate place, or another method may be used. The time for this impregnation is generally about 10 minutes to 1 hour, but is not limited to this.

In particular, in order to shorten the time of the impregnation,
A penetrant or the like may be used. For example,
For example, 0.1 wt% of methanol is added to the total amount of the thermosetting resin liquid.

Further, after the impregnation, the thermosetting resin liquid is dried and cured so that the impregnation rate of the thermosetting resin liquid on the exposed surface of the rock wool substrate is increased. . By drying as described above, the water inside the rock wool base material evaporates, and the curing of the thermosetting resin proceeds. In addition, the exposed surface particularly refers to the front surface, and may be considered including the back surface.

The drying and curing steps may be performed at the same time, as described above, since the water is evaporated and the curing of the thermosetting resin proceeds. May be separated. Generally, the drying temperature is 80 to 2
It is performed at 00 ° C. for 30 minutes to 12 hours,
The curing temperature is 160 to 200 ° C., and the curing time is 30 minutes to 120 minutes. In particular, when the drying temperature is lower than 80 ° C., the drying time is several times as long as the above, and the industrial efficiency is poor. When the drying temperature exceeds 200 ° C., the thermosetting resin is liable to be decomposed.

For example, if the thermosetting resin is cured by 150
When the water content is 10% by weight or more, the temperature of the rock wool base material may not be 150 ° C. or more, and when the water content is 10% by weight or more, the drying step is performed, and the water content is less than 10% by weight. After that, it may be separated as a curing step.

Furthermore, if the back surface of the rock wool substrate is in close contact during the drying and curing steps, the back surface side of the rock wool substrate cannot form a sufficient thermosetting resin layer. And, as a result, it is easy to increase the thermosetting resin content,
Place the rock wool substrate on a net or roll conveyor,
It is preferable to carry out drying and curing steps.

According to the present invention, by adopting such a manufacturing method, the thermosetting resin is impregnated with the thermosetting resin liquid, and then dried to cure the thermosetting resin. While being formed, by impregnation, the water permeating the inside of the rock wool substrate moves to the exposed surface side before evaporating (also referred to as migration).
At that time, the thermosetting resin that has penetrated into the inside also moves to the exposed surface side, and it is possible to more reliably form a layer of the thermosetting resin on the exposed surface. The resin content can be increased. Then, as shown in FIG. 1, the obtained rock wool board (1) itself is easily absorbed by water and has low hardness of the surface, and the heat hardening formed on the front surface (2) and the back surface (4) is performed. By the layer of the conductive resin, it is possible to completely shut out the inhalation of moisture into the inside (3),
As a result, it can be generally used as exterior materials, interior materials, interior base materials, eaves ceiling materials, bus wall materials, bus ceiling materials, floor materials, which require high surface hardness and water resistance. It becomes.

That is, according to the present invention, surface hardness and water resistance can be increased, and as a result, exterior materials, interior materials, interior base materials, eaves ceiling materials, baths, etc., which require high surface hardness and water resistance are required. It can be used as wall material, bus ceiling material, floor material.

The concentration of the thermosetting resin liquid is 1 w
When the content is at least t% and at most 30 wt%, the thermosetting resin that has penetrated into the rock wool substrate will move to the exposed surface side before the water that has also penetrated into the rock wool substrate evaporates. As a result, the layer moves to the exposed surface side, and the layer of the thermosetting resin can be more reliably formed on the exposed surface. That is, the thermosetting resin can be more reliably increased on the exposed surface.

If the concentration of the thermosetting resin liquid is 1 w
When the concentration is less than t%, the concentration of the thermosetting resin liquid is too low, so that even if the thermosetting resin penetrated into the inside of the rock wool substrate moves to the exposed surface side, the thermosetting resin remains on the exposed surface. It is difficult to reliably form the layer. That is, the thermosetting resin cannot be increased on the exposed surface.

Similarly, when the concentration of the thermosetting resin liquid is 3
If the content exceeds 0 wt%, the speed at which the thermosetting resin permeated into the rock wool base material moves to the exposed surface side becomes slower, and it is rather difficult to reliably form the thermosetting resin layer on the exposed surface. Becomes That is, the thermosetting resin cannot be increased on the exposed surface.

Further, if the impregnation is performed until the thermosetting resin liquid permeates the entire rock wool substrate, a layer of the thermosetting resin is surely formed on the exposed surface of the rock wool substrate. At the same time, the moisture and the thermosetting resin penetrate into the inside of the rock wool base material, and then spread, and then the thermosetting resin layer formed on the exposed surface of the rock wool base material is hardened, Before the water inside the wool base material evaporates, it moves to the exposed surface side,
The thermosetting resin that has penetrated into the interior also moves to the exposed surface side, and it becomes possible to more reliably form a layer of the thermosetting resin on the exposed surface. The height can be further reliably increased.

[0027]

Examples of the present invention will be described below.

Example 1 76% of rock wool, starch 7% as a binder, silica sand (No. 7, 8) as an inorganic filler, perlite,
Shirasu balloon, aluminum hydroxide, sepiolite 1
Slurry consisting of 4% and 3% of wax emulsion as a water-proofing agent is formed into a plate shape and dried to a thickness of 15 m.
m, a length of 2730 mm, and a width of 1300 mm, and the entire rock wool base material is used as a thermosetting resin liquid, and has a concentration of 10 w
In a 500 mm wide, 3000 mm long, 1500 mm deep impregnation tank filled with t% phenol resin liquid, Nopco Wet 50 (manufactured by San Nopco) was used as a penetrant in an amount of 0.1 wt% based on the total amount of the thermosetting resin liquid. After being immersed in the whole rock wool substrate for 10 minutes until the thermosetting resin liquid permeates, it is dried at 200 ° C. for 2 hours while moving on a roll conveyor, and further dried at 200 ° C. for 30 minutes. The thermosetting resin was cured while being moved by a roll conveyor for minutes, and a rock wool board as shown in FIG. 1 could be obtained.

Example 2 A rock wool board was obtained in the same manner as in Example 1 except that the thickness of the rock wool substrate was changed to 9 mm, and the paper was dried.

Example 3 A rock wool board was obtained in the same manner as in Example 1 except that the thickness of the rock wool substrate was changed to 20 mm, and the paper was dried.

The average of the resin impregnation rate (also referred to as resin rate) of the rock wool boards obtained in Examples 1 to 3 and the average of the water content of the rock wool boards are summarized in FIGS. 2 and 3, respectively. Was.

The resin impregnation rate was obtained by examining a value obtained by burning the organic component in the resin solution at 600 ° C. and reducing the amount by 30 minutes.
In the case of g, after burning at 600 ° C. for 30 minutes, when it becomes 90 g, the weight was reduced by 10 g, so (100-90) / 100
= 0.1 = 10%, so that the resin impregnation rate is 10
%.

A shown in FIGS. 2 and 3 indicates the impregnation rate and water content of the surface (2) shown in FIG. 1, and B indicates the inside (3) shown in FIG. C indicates the impregnation rate and the water content of the portion, and C indicates the impregnation rate and the water content of the portion of the back surface (4) shown in FIG.

First, as shown in FIG. 2, the resin impregnation rate shows the same value in all of the front surface (2), the inside (3) and the back surface (4) after impregnation, as shown in FIG. It can be seen that the resin is impregnated in the thermosetting resin liquid, and after the impregnation, after drying and after curing, as the process proceeds, the impregnation rate of the resin in the interior (3) decreases, and the surface (2) which is an exposed surface is reduced. Since the impregnation rate of the resin on the back surface (4) increases, a layer of a thermosetting resin is formed on the front surface (2) and the back surface (4) immediately after the impregnation, and after the impregnation, after drying, after curing. It can be said that the thermosetting resin that has permeated into the inside (3) moves to the front surface (2) side and the back surface (4) side while the process proceeds. That is, it can be said that the amount of the thermosetting resin on the exposed surface (2) and the back surface (4) can be increased.

Next, as shown in FIG. 3, after the impregnation, the surface (2), the inside (3) and the back (4) all show high values, and the heat content is substantially uniform. It can be seen that the resin is impregnated with the curable resin liquid. After the impregnation, drying, and curing, the surface (2), the interior (3),
Every portion of the back surface (4) shows a low value, and it can be said that moisture is evaporated in each of the portions during the drying and curing steps. However, the moisture contained in the exposed surface (2) and the back surface (4)
Although it can immediately evaporate to the outside of the rock wool board (1), the water contained in the inside (3) moves to either the front (2) side or the back (4) side. The water cannot evaporate to the outside of the rock wool board (1) unless it passes through the surface of the rock wool substrate (1). It can be said that it can move in either direction between the 2) side and the back (4) side.

Therefore, after being impregnated with the thermosetting resin liquid, the dried thermosetting resin is cured to form a thermosetting resin layer on the exposed surface. Before the moisture that has penetrated into the inside evaporates, it moves to the exposed surface side, and at that time, the thermosetting resin that has penetrated inside also moves to the exposed surface side, and the exposed surface is more reliably heated. A layer of a curable resin can be formed, and it can be said that the amount of the thermosetting resin can be increased on the exposed surface. The thermosetting resin layer completely shuts out the ease of water absorption inherent in the rock wool board itself and the low surface hardness, and as a result, the surface hardness and water resistance are reduced. It can be said that it can be generally used as exterior materials, interior materials, interior base materials, eave ceiling materials, bus wall materials, bus ceiling materials, and floor materials that are strongly required.

That is, according to the present invention, surface hardness and water resistance can be increased, and as a result, exterior materials, interior materials, interior base materials, eaves ceiling materials, baths, etc., which require high surface hardness and water resistance are required. It can be said that it can be used as a wall material, a bus ceiling material, and a floor material.

[0038]

According to the method for manufacturing a rock wool board according to the first aspect of the present invention, the exposed surface is heat-cured by impregnating with a thermosetting resin liquid and then drying and curing the thermosetting resin. A layer of a thermosetting resin is formed and the impregnation moves to the exposed surface side before the moisture permeating the inside of the rock wool substrate evaporates. The exposed portion also moves to the exposed surface side, so that the layer of the thermosetting resin can be more reliably formed on the exposed surface, and the amount of the thermosetting resin can be increased on the exposed surface. The thermosetting resin layer completely shuts out the ease of water absorption inherent in the rock wool board itself and the low surface hardness, and as a result, the surface hardness and water resistance are reduced. Exterior materials, interior materials, interior base materials,
As eaves ceiling material, bus wall material, bus ceiling material, floor material,
It can be used generally.

That is, according to the present invention, surface hardness and water resistance can be increased, and as a result, exterior materials, interior materials, interior base materials, eaves ceiling materials, bath materials and the like, which require high surface hardness and water resistance are required. It can be used as wall material, bus ceiling material, floor material.

According to the method for manufacturing a rock wool board according to claim 2 of the present invention, in addition to the case described in claim 1,
The thermosetting resin that has penetrated the inside of the rock wool substrate moves to the exposed surface side as it moves to the exposed surface side before the moisture that has also penetrated the inside of the rock wool substrate evaporates. As a result, a thermosetting resin layer can be more reliably formed on the exposed surface. That is, the thermosetting resin can be more reliably increased on the exposed surface.

According to the method for manufacturing a rock wool board according to claim 3 of the present invention, in addition to the case described in claim 1 or 2, a layer of a thermosetting resin is surely formed on the exposed surface of the rock wool substrate. Is formed, and once the moisture and the thermosetting resin component penetrate into the inside of the rock wool base material and spread, and then, the thermosetting resin layer formed on the exposed surface of the rock wool base material is hardened. Before the water inside the rock wool substrate evaporates, it moves to the exposed surface side, but at that time, the thermosetting resin that has permeated inside also moves to the exposed surface side, and it is more reliably exposed. A layer of a thermosetting resin can be formed on the surface, and the amount of the thermosetting resin can be more reliably increased on the exposed surface.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a rock wool board obtained by a method for manufacturing a rock wool board according to one embodiment of the present invention.

FIG. 2 is a graph showing a change in resin impregnation rate in each step in a method for manufacturing a rock wool board according to an embodiment of the present invention.

FIG. 3 is a graph showing a change in water content of each step in a method for manufacturing a rock wool board according to an embodiment of the present invention.

──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Etsuro Otsuki 1048 Kadoma Kadoma, Osaka Prefecture Matsushita Electric Works, Ltd. References JP-A-5-263347 (JP, A) JP-A-48-102122 (JP, A) JP-A-9-254112 (JP, A) JP-A-9-208341 (JP, A) −201814 (JP, A) (58) Fields surveyed (Int. Cl. ⁷ , DB name) D21J 1/12

Claims (3)

(57) [Claims] 1. An impregnation of the whole rock wool substrate, which is made into a plate shape by a wet method and dried, with a thermosetting resin liquid, and then impregnated with the same thermosetting resin liquid on an exposed surface of the rock wool substrate. A method for manufacturing a rock wool board, comprising drying the thermosetting resin so as to increase the rate. 2. The method according to claim 1, wherein the concentration of the thermosetting resin liquid is 1 wt%.
The method for producing a rock wool board according to claim 1, wherein the content is at least 30 wt% or less. 3. The method for producing a rock wool board according to claim 1, wherein the impregnation is performed until the thermosetting resin liquid permeates the entire rock wool substrate.