JP3470522B2 - 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 rock wool boards used as building materials such as wall materials, ceiling materials, eaves ceiling materials, floor materials and the like.

[0002]

2. Description of the Related Art Conventionally, calcium silicate boards, insulation boards, particle boards, cement boards, etc. have been used as building materials, but rock wool boards are also effective building materials from the viewpoint of heat insulation and lightweight. one of. However, since the rock wool board has a higher water absorption rate than the other building materials described above, there are problems that the dimensional change during water absorption is large and the water resistance strength (bending strength during water absorption) is reduced. Therefore, a rockwool board containing a thermosetting resin has been proposed in order to suppress the dimensional change when absorbing water and improve the water resistance strength.

The rock wool board containing the thermosetting resin is formed by wet-making a rock wool slurry prepared by mixing rock wool and water with a paper making machine to form a wet mat, and then wet. Dry the mat to make a dry rock wool board, then apply thermosetting resin to the surface of this dry rock wool board to impregnate the dry rock wool board with thermosetting resin, and then dry rock wool board It is manufactured by heating the resin to cure the thermosetting resin.

In this method, however, the dry rock wool plate after the wet mat has been dried is impregnated with the thermosetting resin, so that the thermosetting resin cannot be uniformly impregnated in the thickness direction. Therefore, it has not been possible to obtain a rockwool board which has improved strength or reduced dimensional change when absorbing water as compared with rockwool board not impregnated with a thermosetting resin.

Therefore, after the thermosetting resin liquid is applied to the surface of the wet mat before being dried, the thermosetting resin liquid is then impregnated into the wet mat by suction dehydration from the back side of the wet mat. BACKGROUND ART Rock wool boards are manufactured by heating a wet mat to cure a thermosetting resin. By using this method, it is possible to uniformly impregnate the wet mat with the thermosetting resin rather than impregnating the dry rock wool plate with the thermosetting resin as described above. There has been a problem that the amount of impregnation becomes small and a high-strength rock wool board cannot be obtained.

[0006]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a method for producing a rockwool board that can obtain a rockwool board having high strength, and in addition to this, lock it after drying. It is an object of the present invention to provide a method for producing a rock wool board that can prevent the wool board from warping.

[0007]

A method for manufacturing a rock wool board according to claim 1 of the present invention comprises forming a wet mat 2 by making rock wool into a paper .
While sucking and dehydrating from the back side, on the surface of the wet mat 2
After the thermosetting resin liquid 4 is impregnated into the wet mat 2 by applying the thermosetting resin liquid 4, the same thermosetting resin as the thermosetting resin liquid 4 is used on the back surface of the wet mat 2. It is characterized in that another prepared thermosetting resin liquid 5 is applied.

In addition to the structure of claim 1, the invention of claim 2 of the present invention is characterized in that the thermosetting resin liquid 5 is applied to the back surface of the wet mat 2 using a roll coater 10. To do.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below. FIG. 1 shows an example of the embodiment. First, a rock wool in a rock wool slurry 11 prepared by mixing rock wool and water is wet-processed by a round-net paper-making machine 1 and then peeled from the paper-making machine 1 to form a long plate-like material. The wet mat 2 is formed. The water content of the wet mat 2 after papermaking can be set to 60 to 200% by weight. Water content of wet mat 2 is 60% by weight
If it is less than the predetermined value, it is impossible to obtain a predetermined thickness as a rock wool board (thickness necessary to secure strength when used as a building material etc.), and the wet mat 2 has a water content of 200% by weight. When it exceeds, the wet mat 2 contains too much water and the strength of the wet mat 2 cannot be obtained. In either case, the production of the rock wool board is difficult and unrealistic.

Next, the wet mat 2 is conveyed by a roll or the like to a position above the vacuum box 3, and the inside of the vacuum box 3 is decompressed by a vacuum pump connected to the vacuum box 3 to suck and dehydrate the wet mat 2 from the back side. while doing,
The thermosetting resin liquid 4 is overflowed from the overflow coater 6 and applied (sprayed) onto the surface of the wet mat 2.

By applying the thermosetting resin liquid 4 to the surface of the wet mat 2 while sucking and dehydrating from the back surface of the wet mat 2 as described above, the moisture contained in the wet mat 2 is removed from the back surface of the wet mat 2. While removing from the side, the thermosetting resin liquid 4 applied to the surface of the wet mat 2 can be sucked to impregnate the wet mat 2 with the thermosetting resin liquid 4. Therefore, the wet mat 2
Further, the thermosetting resin can be impregnated almost uniformly (the variation of the resin distribution in the thickness direction is 1 to 2%). That is, the wet mat 2 after papermaking has a water content of 60 to 200% by weight.
The wet mat 2 having such a high water content does not impregnate even when the thermosetting resin liquid 4 is applied, because the wet mat 2 exceeds the amount of water capable of retaining water. However, when the thermosetting resin liquid 4 is applied to the surface of the wet mat 2 while sucking and dehydrating from the back surface side of the wet mat 2 as described above, the moisture impregnated in the wet mat 2 becomes the thermosetting resin liquid 4. Therefore, the wet mat 2 can be impregnated with the thermosetting resin almost uniformly.

As the thermosetting resin liquid 4, an aqueous solution in which a phenol resin, a melamine resin, a urea resin, or a mixture thereof is dissolved in water and the concentration is set to 1 to 55% by weight can be used. Thermosetting resin liquid 4
Is less than 1% by weight, the amount of the thermosetting resin impregnated into the wet mat 2 is small, and the significance of impregnating the rock wool board with the thermosetting resin is lost. When the concentration of the liquid 4 exceeds 55% by weight, the concentration becomes higher than that of the undiluted solution, and the viscosity is too high to apply the solution, which is not realistic.

When the water content of the wet mat 2 is 100% by weight (the water content of the standard wet mat 2), the coating amount of the thermosetting resin liquid 4 is relative to the water content (retained water content). It is preferably 60 to 200% by weight.
This is to apply 50% by weight of thermosetting resin liquid 4 to the wet mat 2 having a water content of 100% by weight with respect to the amount of water contained in the wet mat 2, and set the degree of vacuum during suction dehydration to 500 m.
This is because the uniform impregnating property of the thermosetting resin into the wet mat 2 tends to be slightly lowered when mHg is set.

Therefore, the wet mat 2 having a water content of 100% by weight has a water content of 60 relative to the wet mat 2.
A thermosetting resin liquid 4 of weight% is applied and the vacuum degree at the time of suction dehydration is set to 400 mmHg, or a wet mat 2 having a water content of 100% by weight has a water content of 80% by weight with respect to the water content of the wet mat 2. Apply thermosetting resin liquid 4,
The vacuum degree during suction dehydration is set to 200 mmHg, or 100% by weight of the thermosetting resin liquid 4 with respect to the water content of the wet mat 2 is applied to the wet mat 2 having a water content of 100% by weight. Vacuum degree of 100mmH
g or, in the wet mat 2 having a water content of 100% by weight, the moisture content of the wet mat 2 is 15
0% by weight of thermosetting resin liquid 4 is applied and the degree of vacuum during suction dehydration is set to 80 mmHg, or 200% by weight with respect to the water content of wet mat 2 having a water content of 100% by weight. By applying the thermosetting resin liquid 4 of, and setting the degree of vacuum during suction dehydration to 60 mmHg,
It is preferable not to reduce the uniform impregnation property of the thermosetting resin into the wet mat 2.

The water content of the wet mat 2 after suction dehydration can be set to 60 to 200% by weight. When the water content of the wet mat 2 is less than 60% by weight, a predetermined thickness as a rock wool board (thickness necessary for securing strength when used as a building material etc.) cannot be obtained, and Water content of wet mat 2 is 2
If it exceeds 100% by weight, the water content of the wet mat 2 is too large to obtain the strength of the wet mat 2, and in any case, the production of rock wool board is difficult and impractical.

The vacuum degree during the above-mentioned suction dehydration is 60 to 7
It can be set to 60 mmHg. Vacuum degree is 60m
If it is less than mHg, the suction force becomes insufficient, and it takes too much time to dehydrate the water contained in the wet mat 2 and impregnate it with the thermosetting resin liquid 4. The vacuum degree of 760 mmHg is absolutely 0 atm, and it cannot be higher than this. In addition to the use of the overflow coater 6, the thermosetting resin liquid 4 may be applied to the wet mat 2 by using a flow coater, spraying, or a roll coater.

After the wet mat 2 is impregnated with the thermosetting resin liquid 4 from the surface in this manner, the thermosetting resin liquid 5 is added to the back surface of the wet mat 2 by using a roll coater 10 or a spray coater in a solid content of 50. The entire surface is coated and impregnated with a coating amount of ˜250 g / m ² . In the step of impregnating the wet mat 2 with the thermosetting resin liquid 4 from the surface, only the necessary minimum amount of the thermosetting resin liquid 4 is applied to the surface of the wet mat 2 and the thermosetting resin liquid 4 is sucked. Even if the wet mat 2 is pulled to the back side, the amount of the thermosetting resin impregnated on the back side of the wet mat 2 is smaller than that on the front side. Therefore, in the present invention, by additionally applying the thermosetting resin liquid 5 to the back surface of the wet mat 2, the insufficient impregnation of the thermosetting resin on the back surface side of the wet mat 2 is additionally applied to the back surface of the wet mat 2. The wet mat 2 is supplemented with the thermosetting resin liquid 5 so that the thermosetting resin is uniformly impregnated.

As the thermosetting resin liquid 5 additionally applied to the back surface of the wet mat 2, one prepared using the same thermosetting resin as the thermosetting resin liquid 4 applied to the front surface side is used. To do. That is, when the phenol resin aqueous solution is used as the thermosetting resin liquid 4, it is preferable to use the phenol resin aqueous solution also as the thermosetting resin liquid 5, and as the thermosetting resin liquid 4, a mixture of a phenol resin and a melamine resin is used. When an aqueous solution is used, the thermosetting resin liquid 5 is also an aqueous solution of a mixture of a phenol resin and a melamine resin.

By using the same thermosetting resin as described above, the curing shrinkage rate and gelation time of the thermosetting resin on the front surface side and the back surface side of the wet mat 2 can be made the same, and the drying step can be performed. Thus, the wet mat 2 can be uniformly dried and cured from both the front surface side and the back surface side, and a rock wool board with less warpage can be obtained. The concentration of the thermosetting resin liquid 5 additionally applied to the back surface of the wet mat 2 is 1 to 55 for the same reason as above.
Although it can be set to the weight%, it does not necessarily have to be the same as the concentration of the thermosetting resin liquid 4 applied to the surface, and may be the same concentration. By adjusting the concentration of the thermosetting resin liquid 5 in this way, the amount of the thermosetting resin impregnated into the wet mat 2 can be controlled so that the resin distribution of the wet mat 2 becomes more uniform. Is. Furthermore, by applying the thermosetting resin liquid to the back surface of the wet mat 2 using the roll coater 10, the thermosetting resin liquid 5 can be uniformly applied to the wet mat without causing liquid dripping. is there.

After that, the wet mat 2 impregnated with the thermosetting resin is introduced into the dryer 20 and the temperature is 160 to 200 ° C.
By heating and drying the wet mat 2 at the temperature of 30 to 120 minutes and curing the thermosetting resin contained in the wet mat 2, it is possible to form a rock wool board having a water content of 1% by weight or less. . In the rock wool board, the thermosetting resin liquid 4 is applied to the surface of the wet mat 2 while sucking and dehydrating from the back surface side of the wet mat 2, and the thermosetting resin liquid 5 is further applied to the back surface of the wet mat 2. Since it is formed by additional coating,
Since the thermosetting resin is uniformly contained in the thickness direction, bending strength can be increased and warpage can be reduced.

[0021]

EXAMPLES The present invention will be described in detail below with reference to examples. (Example) Rock wool is formed into a paper, and the water content is 100% by weight.
Wet mat 2 is formed, and while the wet mat 2 is sucked and dehydrated from the back side at a vacuum degree of 100 mmHg, an aqueous phenol resin solution having a concentration of 10% by weight as a thermosetting resin liquid 4 is applied to the surface of the wet mat 2 by an overflow coater. 6 was applied and the wet mat 2 was impregnated with the phenol resin. The coating amount of the thermosetting resin liquid 4 was set to 100% by weight with respect to the water content of the wet mat 2.
Then concentration of 20 wt% of a phenolic resin aqueous solution 700 g / m ² as the thermosetting resin liquid 5 by using a roll coater on the back of the wet mat ² (140g / m 2 by solid content)
Was additionally applied. Next, wet mat 2 18
It was heated at a temperature of 0 ° C. for 75 minutes to dry the wet mat 2 and cure the phenol resin impregnated in the wet mat 2 to prepare a rock wool board.

(Comparative Example 1) A rock wool board was prepared in the same manner as in the above example except that a 20% by weight melamine resin aqueous solution was used as the thermosetting resin liquid 5. (Comparative Example 2) A rock wool board was prepared in the same manner as in the above Example except that the thermosetting resin liquid 5 was not applied to the back surface of the wet mat 2.

In order to evaluate the variation (resin ratio) of the resin distribution in the thickness direction of the rock wool boards of the above-mentioned Examples and Comparative Examples 1 and 2, the rock wool boards were made into three layers of the surface layer, the middle layer and the back layer in the thickness direction. The sample was divided into two parts, and each was left in a furnace at 600 ° C. for 30 minutes to measure the rate of weight loss. The bending strengths of the rock wool boards of Examples and Comparative Examples 1 and 2 were measured in both a dry state (air dry) and a water absorption state (a state in which hot water was absorbed) according to JIS A 1405 No. 5 test piece. Moreover, the warp per 1 m of the rock wool boards of Examples and Comparative Examples 1 and 2 was measured. Table 1 shows each measurement result.

[0024]

[Table 1]

When the rock wool boards of Example and Comparative Examples 1 and 2 were compared, the flexural strength of the Example was higher than that of Comparative Examples 1 and 2. Judging from the resin ratio, the same thermosetting resin was uniformly impregnated on the surface layer side and the back layer side in the rock wool boards of the Examples, whereas the back surface of the rock wool boards of Comparative Examples 1 and 2 was It is considered that this is because the amount of the thermosetting resin impregnated on the side is small.

When the rock wool boards of Example and Comparative Example 1 were compared with each other, no warpage occurred in the Example, but warpage occurred in the Comparative Example 1. This is because the same thermosetting resin was impregnated on the front surface side and the back surface side of the wet mat 2 in the example, so that the wet mat 2 is dried in the drying step.
Was able to be uniformly dried and cured from both the front surface side and the back surface side, but in Comparative Example 1, since the front surface side and the back surface side of the wet mat 2 were impregnated with different thermosetting resins,
This is probably because the wet mat 2 could not be uniformly dried and cured from both the front surface side and the back surface side in the drying step.

[0027]

As described above, the invention according to claim 1 of the present invention forms a wet mat by making rock wool into paper, and suction-dehydrates the back surface of the wet mat while dewatering.
By applying a thermosetting resin liquid to the surface of the mat
After impregnating the wet mat with the thermosetting resin liquid,
Since applying the other thermosetting resin liquid prepared with the thermosetting resin liquid of the same thermosetting resin on the rear surface of the wet mat, the impregnated lack of thermosetting resin on the back side of the wet mat The wet mat can be uniformly impregnated with the thermosetting resin by supplementing it with the thermosetting resin liquid additionally applied to the back surface of the wet mat, and a high-strength rock wool board can be obtained. Moreover a thermosetting resin liquid applied to the surface of the wet mat, so prepared with a thermosetting resin liquid and the same kind of thermosetting resin coated on the rear surface of the wet mat, the surface side of the wet mat cure shrinkage of the thermosetting resin in the back surface side and the gel time and can be the same, the wet mat drying process can be cured by evenly dried from both the front and rear sides and It is possible to obtain a rock wool board with less warpage.

As described above, according to the second aspect of the present invention, since the thermosetting resin liquid is applied to the back surface of the wet mat by using the roll coater, the thermosetting resin liquid is uniformly heat-cured without causing liquid dripping. The resin composition can be applied to the wet mat.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing an example of an embodiment of the present invention.

[Explanation of symbols]

2 wet mat 4 Thermosetting resin liquid 5 Thermosetting resin liquid 10 roll coater

─────────────────────────────────────────────────── ─── Continuation of the front page (56) Reference JP 62-119004 (JP, A) JP 9-201814 (JP, A) JP 61-79603 (JP, A) JP 61- 295009 (JP, A) JP 63-237904 (JP, A) Actual development 60-1472 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) D21H 11/00-27 / 42 B05D 1/00-7/26

Claims (2)

(57) [Claims] 1. Rock wool is formed into a wet mat , and the wet mat is sucked and dehydrated from the back side.
The surface of the wet mat with a thermosetting resin.
After the thermosetting resin liquid is impregnated with and the other surface of the wet mat is coated with another thermosetting resin liquid prepared using the same thermosetting resin liquid as the above thermosetting resin liquid. A method for producing a rock wool board, which is characterized in that 2. The method of manufacturing a rock wool board according to claim 1, wherein the thermosetting resin liquid is applied to the back surface of the wet mat using a roll coater.