JP3635806B2 - Manufacturing method of mineral fiberboard - Google Patents

Description

【００１５】
【発明の効果】
表１に示す抄造性及び物性から理解される通り本発明の製造方法によると抄造時濾水時間は２０〜２３秒と短く、また抄造後厚さを最終製品厚さよりも大巾に薄く設定できるためウエットマットの絶対含水量が大巾に下がるのでライン速度指数も一般従来品を代表する比較例１の１００に比べ１７５〜２４５と１．７倍以上と極めて生産性に優れる。本発明方法で製造した鉱物質繊維板の物性は乾燥後密度が１８０〜２８０ｋｇ／ｍ3 と目的の軽量化を達成し、吸音率においても０．６０〜０．７５と十分な効果が認められる。さらに、その鉱物質繊維板は全層に亘って虫喰模様状態を生じているため、表面切削、立体切削等によって形成した表面に虫喰模様状の自然な凹凸模様が現れ、このため、ロールやサンドブラスト等の機械加工による模様付けが不要となり、自然な凹凸模様を機械加工せずに付与する本発明の大切な目的も十分に達成することができた。[0001]
[Industrial application fields]
TECHNICAL FIELD The present invention relates to a wet manufacturing method of a mineral fiber board that is excellent in lightness, sound absorption, and productivity mainly composed of mineral fibers such as slag and that can give a natural uneven pattern without machining.
[0002]
[Prior art]
Mineral fiberboard by wet manufacturing method, which is mainly made of mineral wool, is used for ceiling interior materials due to its fireproof performance, sound absorption performance and design. However, the conventional mineral fiberboard is required to further improve sound absorption and reduce weight. In addition, conventional design application methods for molded plates by wet manufacturing methods include roll embossing, roll fisher, roll press, sandblast solid processing, etc., all of which require mechanical equipment, so the design application process becomes rate-limiting in productivity. Since the pattern is mechanical, it becomes artificial and regular, and a natural feeling cannot be obtained. Moreover, since the pattern by the roll or sandblast is applied only to the surface layer, the pattern cannot be left in the valley when three-dimensional processing such as a cube is used together. It was practically impossible to leave a pattern over the entire layer of the material by the wet manufacturing method.
[0003]
[Problems to be solved by the invention]
The present invention economically solves the above-mentioned potential problems of mineral fiber board, is excellent in light weight, sound absorption, productivity, and wet production of mineral fiber board that can impart a natural uneven pattern without machining It is to provide a method.
[0004]
[Means for Solving the Problems]
The problems are: mineral fiber 60-90%, organic binder 2-19%, inorganic fine fiber 1-20%, flocculant 0.5-3%, diameter after expansion is 1.0- The composition is composed of 0.5 to 7% by weight of thermally expandable fine particles having a diameter of 3.0 mm, an expansion ratio of a diameter of 3 times or more, and an expansion start temperature of 50 to 105 ° C. The slurry is then cut into a mat through a paper making process, and then in the drying process, the thermally expandable fine particles in the mat are heated and expanded, and the expansion of the thermally expandable fine particles is performed before the setting of the organic binder is set. This is solved by a method for producing a mineral fiberboard, characterized in that after the setting of the organic binder is cured, the thermally expandable fine particles that have expanded are melted and bubble-breaked to form a worm-eating pattern throughout the entire layer. Is done.
[0005]
DETAILED DESCRIPTION OF THE INVENTION
The mineral fiber according to the present invention is mineral cotton, rock wool or the like, and the amount used is 60 to 90% by weight.
[0006]
The organic binder according to the present invention is used in an amount of 2 to 19% by weight for binding components such as mineral fibers in resin, starch, beaten pulp and the like. If the amount is less than 2% by weight, the strength to bind the mineral fiber is insufficient, and there is a problem in maintaining the strength of the mineral fiber board. If the total organic component exceeds 20% by weight, the quasi-incombustibility cannot be cleared in the fire prevention performance. The upper limit of the organic binder is 19% by weight.
[0007]
The inorganic fine fibers according to the present invention are sepiolite, attapulgite, and the like, and contribute to the improvement of strength properties as a binder and a yield improving material for organic binders and thermally expandable resin fine particles. The amount used is 1 to 20% by weight. If it is less than 1% by weight, the effect of improving the yield and improving the physical properties is insufficient, and if it exceeds 20% by weight, the content of the mineral fiber of the main raw material decreases and the density increases, and the paper making process This is not preferable because the production speed decreases due to the deterioration of the drainage.
[0008]
The flocculant according to the present invention includes polyacrylamide, polyacrylamide-modified product, aluminum sulfate and the like, and is used in an amount of 0.5 to 3% by weight. If it is less than 0.5% by weight, a sufficient effect cannot be obtained, and even if it exceeds 3% by weight, no further increase in the effect is observed.
[0009]
The thermally expandable fine particles according to the present invention include one or more blowing agents such as propane, butane, pentane, and isobutane in a resin such as styrene, polyethylene, polypropylene, a copolymer of acrylonitrile and vinylidene chloride, and an ethylene vinyl acetate copolymer. Fine particles encapsulated above. The specific gravity of these fine particles is preferably close to 1.0 in order to obtain a uniform slurry. The fine particles of the heat-expandable resin, the diameter after expansion is 1.0Mm～3.0Mm, more than three times expansion ratio of the diameter, and expansion starting temperature is used those of 50 to 105 ° C.. The reason why the diameter after expansion is 1.0 mm to 3.0 mm is that if the thickness is less than 1.0 mm, a good insect-eating pattern is not formed, and if it exceeds 3.0 mm, the layer structure becomes rough and the strength and hardness are insufficient. The reason why the expansion ratio of the diameter is 3 times or more is to obtain a sufficient light weight effect of the mineral fiber board. The reason why the expansion start temperature is 50 to 105 ° C. is to avoid expansion at room temperature and because it is preferable that the expansion is started before the curing of the binder is started and the expansion is finished before the binder is cured. The amount of the thermally expandable fine particles used is 0.5 to 7% by weight. If the amount is less than 0.5% by weight, sufficient lightness cannot be obtained. The heat-expandable fine particles according to the present invention are fine particles when present in the raw slurry, and since the specific gravity is around 1.0, they are easily and uniformly dispersed in the slurry, and density spots do not occur in the product. After the paper making process, it is cut into a mat shape, and in the drying process, the thermally expandable fine particles are heated and when the temperature reaches the expansion temperature, the mat begins to expand and the mat increases in thickness, expanding before the blended binder is cured and set. Is over. When all the water in the mat is evaporated, the mat becomes almost dry mat and the setting of the binder is almost finished. The temperature of the mat further increases, but the thermally expandable fine particles expanded in this process reach their melting point. Therefore, the thermally expandable fine particles melt and foam and return to the volume before expansion, and act as a part of the binder after drying. The void formed by the expanded resin fine particles remains as it is, and works effectively as a sound absorbing effect and a heat insulating effect.
[0010]
The mineral fiber board of the present invention is a blending process in which mineral fibers, organic binders, inorganic fine fibers, flocculants and thermally expandable fine particles are added to water in a predetermined ratio and uniformly dispersed, and the total amount of the above components is A slurry of about 5% is obtained. The slurry is dehydrated in a paper making process, cut to a predetermined size, and then dried and cured to obtain an original plate. The original plate is sent to the cosmetic finishing process, and after the decorative coating or three-dimensional cutting, the decorative coating is applied to obtain the final product.
Conventional sound absorption processing such as pin holes is unnecessary because the material is porous, and since it is in a worm-eating pattern state over the entire layer, patterning with a roll is also unnecessary.
[0011]
【Example】
[Examples 1 to 4]
Each component is added to water at the blending ratio shown in Table 1 to obtain a slurry which is uniformly dispersed and the total component becomes 5% by weight, made into paper by a long net paper machine, dried and cured, and subjected to surface cutting and cosmetic cutting. To obtain a mineral fiberboard of the present invention.
[0012]
[Comparative Examples 1-4]
Each component is added to water at the blending ratio shown in Table 1 to obtain a slurry which is uniformly dispersed and the total component becomes 5% by weight, made into paper by a long net paper machine, dried and cured, and subjected to surface cutting and cosmetic cutting. To obtain a mineral fiberboard for comparison.
[0013]
The papermaking properties of Examples 1 to 4 and Comparative Examples 1 to 4 and the physical properties of the obtained mineral fiberboard were measured and shown in Table 1.
[0014]
[Table 1]

[0015]
【The invention's effect】
As understood from the papermaking properties and physical properties shown in Table 1, according to the production method of the present invention, the draining time at the time of papermaking is as short as 20 to 23 seconds, and the post-papermaking thickness can be set much thinner than the final product thickness. Therefore, since the absolute water content of the wet mat is greatly reduced, the line speed index is 175 to 245, which is 1.7 times or more higher than that of 100 of Comparative Example 1, which represents a general conventional product, and is extremely excellent in productivity. As for the physical properties of the mineral fiber board produced by the method of the present invention, the density after drying is 180 to 280 kg / m @ 3 and the intended weight reduction is achieved, and a sufficient effect of 0.60 to 0.75 is recognized also in the sound absorption coefficient. Furthermore , since the mineral fiberboard has a worm-eating pattern throughout the entire layer, a natural concavo-convex pattern appears on the surface formed by surface cutting, three-dimensional cutting, etc. The patterning by machining such as sand blasting or the like is no longer necessary, and the important object of the present invention that gives a natural uneven pattern without machining can be sufficiently achieved.

Claims (1)

Mineral fiber 60-90 wt%, organic binder 2-19 wt%, inorganic fine fiber 1-20 wt%, flocculant 0.5-3 wt%, diameter after expansion is 1.0-3.0 mm Yes, the expansion ratio of the diameter is 3 times or more and the expansion start temperature is 50 to 105 ° C., and 0.5 to 7% by weight of thermally expandable fine particles as a composition component is uniformly dispersed in water to form a slurry. In the drying process, the thermally expandable fine particles in the mat are heated and expanded in the drying process, and the expansion of the thermally expandable fine particles is terminated before setting the organic binder to be cured. Next, a method for producing a mineral fiber board, wherein the thermally expandable fine particles expanded after the setting of the organic binder is melted and bubble-breaked to form an insect-eating pattern throughout the entire layer .