JP4939144B2 - Mineral fiberboard and manufacturing method thereof - Google Patents

Mineral fiberboard and manufacturing method thereof Download PDF

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JP4939144B2
JP4939144B2 JP2006213967A JP2006213967A JP4939144B2 JP 4939144 B2 JP4939144 B2 JP 4939144B2 JP 2006213967 A JP2006213967 A JP 2006213967A JP 2006213967 A JP2006213967 A JP 2006213967A JP 4939144 B2 JP4939144 B2 JP 4939144B2
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滋 森下
玉村耕造
竹田康浩
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大建工業株式会社
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本発明は鉱物質繊維板、特に、傾斜した密度の層を有する鉱物質繊維板およびその製造方法に関する。   The present invention relates to a mineral fiberboard, and more particularly to a mineral fiberboard having a graded density layer and a method of manufacturing the same.
従来、ロックウール板等の鉱物質繊維板は、軽量で断熱性および吸音性に富むことから、一般住宅,店舗はもちろんのこと、美術館や図書館等の公的な建物においても天井材、壁材として用いられているが、軽量性,断熱性および吸音性について更なる向上が求められている。そこで、軽量化のために軽量骨材を高配合し、全体が均一な低密度の鉱物質繊維板を製造することも考えられる。しかし、乾燥,硬化させたとしても、0.3g/cm以下、特に0.2g/cm以下の低密度鉱物質繊維板の場合は、成形性が著しく低下する。このため、製造工程における搬送時に少しの振動を加えても崩れてしまい、生産性が著しく低下するだけでなく、鉱物質繊維板の表面性も失われる。 Conventionally, mineral fiber boards such as rock wool boards are lightweight and have excellent heat insulation and sound absorption properties. Therefore, ceiling materials and wall materials can be used not only in ordinary houses and stores, but also in public buildings such as museums and libraries. However, there is a need for further improvements in lightness, heat insulation and sound absorption. Therefore, it is also conceivable to produce a low density mineral fiber board having a uniform overall structure by blending lightweight aggregates for weight reduction. However, even if it is dried and cured, the formability of the low density mineral fiberboard of 0.3 g / cm 3 or less, particularly 0.2 g / cm 3 or less, is remarkably lowered. For this reason, even if a slight vibration is applied at the time of conveyance in the manufacturing process, it collapses, not only the productivity is remarkably lowered, but also the surface property of the mineral fiber board is lost.
また、例えば特許文献1に示すように、鉱物質繊維を主成分とし、特定の熱膨張性微粒子を原料として配合し、湿式抄造で製造することにより、軽量性、吸音性および生産性を向上させる鉱物質繊維板が提案されている。
特開平10−72798号公報
Moreover, as shown in Patent Document 1, for example, mineral fiber is a main component, specific heat-expandable fine particles are blended as raw materials, and manufactured by wet papermaking, thereby improving lightness, sound absorption and productivity. Mineral fiberboard has been proposed.
JP-A-10-72798
しかしながら、前述の鉱物質繊維板の製造工程では、より均一で低密度の鉱物質繊維板を製造しようとすると、多量の熱膨張性微粒子が必要となる反面、相対的に鉱物質繊維等の量が減少するので、所望の成形性を確保することが困難であるとともに、熱膨張性微粒子を適度に膨張させるための加熱時間,温度等のコントロールが必要となるので、生産性に改良の余地がある。また、熱膨張性微粒子を混入することにより、不燃性が低下するという問題点がある。   However, in the above-described manufacturing process of the mineral fiber board, when trying to manufacture a more uniform and low density mineral fiber board, a large amount of thermally expandable fine particles is required, but the amount of mineral fibers and the like is relatively large. Therefore, it is difficult to ensure the desired formability, and it is necessary to control the heating time and temperature for appropriately expanding the thermally expandable fine particles, so there is room for improvement in productivity. is there. Moreover, there is a problem that nonflammability is reduced by mixing thermally expandable fine particles.
本発明は、前記問題点に鑑み、成形性や表面性を確保しながらも、軽量で取扱性,生産性が良く、吸音性,断熱性,不燃性に優れた鉱物質繊維板およびその製造方法を提供することを課題とする。   In view of the above problems, the present invention is a mineral fiber board that is lightweight, easy to handle and productive, and excellent in sound absorption, heat insulation, and incombustibility while ensuring formability and surface properties, and a method for producing the same It is an issue to provide.
本発明者らは前述の問題点に鑑み、裏面側の表皮層を高密度とし、裏面から芯部に向かって低密度となるように密度を傾斜させ、芯部から表面に向かって高密度となるように密度傾斜させることにより、成形性,表面性を確保し、取扱性,生産性,不燃性を損なうことなく、軽量で吸音性,断熱性に優れた鉱物質繊維板を得られることを知見し、これに基づいて本願発明を完成した。   In view of the above-mentioned problems, the inventors have made the skin layer on the back side high density, inclined the density so as to become low density from the back surface toward the core, and high density from the core to the surface. It is possible to obtain a mineral fiberboard that is lightweight and has excellent sound absorption and heat insulation properties without sacrificing handleability, productivity, and incombustibility, by inclining the density so that Based on this knowledge, the present invention has been completed.
本発明にかかる鉱物質繊維板は、前記課題を解決すべく、鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有し、かつ、平均密度が0.10〜0.30g/cmとしてある。 The mineral fiberboard according to the present invention includes a mineral fiber, an inorganic lightweight aggregate, and a binder as main components to solve the above-described problem, and a layer having a gradient density that decreases from the back surface toward the core. In addition, it has a gradient density layer that increases in density from the core toward the surface, and the average density is 0.10 to 0.30 g / cm 3 .
本発明によれば、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有している。このため、裏面側の表皮層も表面側の表皮層も高密度であり、所定の強度を有するので、取扱性が良いだけでなく、成形性,表面性がよいので、裏面あるいは表面をロール等でピン孔加工やエンボス模様を付けることができるとともに、化粧シートを貼着したり、あるいは、塗装を施して化粧板を製造できる。芯部の層が低密度であるので、鉱物質繊維板の平均密度としては0.10〜0.30g/cmである。このため軽量であり、吸音性,断熱性に優れている。また、鉱物質繊維と無機質軽量骨材が主成分なので、不燃性を有している。 According to this invention, it has the layer of the gradient density which becomes a low density toward a core part from a back surface, and has the layer of the gradient density which becomes a high density toward a surface from a core part. For this reason, both the skin layer on the back side and the skin layer on the front side have a high density and have a predetermined strength, so that not only the handling property is good, but also the moldability and surface property are good. In addition to pin hole processing and embossed pattern, a decorative sheet can be applied by applying a decorative sheet or painting. Since the core layer has a low density, the average density of the mineral fiber board is 0.10 to 0.30 g / cm 3 . For this reason, it is lightweight and excellent in sound absorption and heat insulation. Moreover, since mineral fiber and inorganic lightweight aggregate are the main components, it has nonflammability.
本発明にかかる別の実施形態としては、裏面から芯部へ向かって低密度となる傾斜密度の層と、残る芯部から表面へ向かって高密度となる傾斜密度の層とを異なる成分組成で形成してもよい。   As another embodiment according to the present invention, a gradient density layer that decreases in density from the back surface toward the core and a gradient density layer that increases in density from the remaining core toward the surface have different component compositions. It may be formed.
本実施形態によれば、適材適所の成分組成となるので、より軽量で吸音性,断熱性,取扱性に優れた鉱物質繊維が得られる。   According to this embodiment, since the component composition of the appropriate material is the right place, a mineral fiber that is lighter in weight, excellent in sound absorption, heat insulation, and handleability can be obtained.
本発明にかかる鉱物質繊維板の製造方法は、鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、凝集剤とともに水に投入,混合し、フロックが生じたスラリーとする工程と、前記スラリーを円網式抄造機で湿式抄造し、裏面から表面に向かって低密度となる傾斜密度を有するウェットマットを形成する工程と、前記ウェットマットにプレスを施し乾燥する工程とを有し、前記スラリーの生成工程では、前記無機質軽量骨材を35〜50重量%添加しかつ凝集剤を0.45〜2.0重量%添加することで、該スラリーを、前記ウェットマットの形成工程で湿式抄造により裏面から表面に向かって低密度となる傾斜密度の層を有するウェットマットを形成できる程度の大きさのフロックが生じたスラリーとする。 The method for producing a mineral fiber board according to the present invention comprises a mineral fiber, an inorganic lightweight aggregate, and a binder as main components, and is added to water together with a flocculant and mixed to form a floc-generated slurry, The slurry is wet-made with a circular net-type machine, and has a step of forming a wet mat having a gradient density that decreases from the back surface to the surface, and a step of pressing the wet mat and drying, In the slurry production step, 35-50% by weight of the inorganic light-weight aggregate and 0.45-2.0% by weight of the flocculant are added, so that the slurry is subjected to wet papermaking in the wet mat forming step. Thus, a slurry having flocs large enough to form a wet mat having a gradient density layer that decreases in density from the back surface to the front surface is obtained.
本製造方法による鉱物質繊維板は、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有し、かつ、平均密度が0.10〜0.30g/cmである。 The mineral fiber board according to the present manufacturing method has a gradient density layer that decreases in density from the back surface toward the core portion, a gradient density layer that increases in density from the core portion toward the surface, and The average density is 0.10 to 0.30 g / cm 3 .
本工程で形成されたウェットマットは、搬送時には裏面側が下側となるが、裏面側の表皮層が高密度であるので、振動による型崩れがしにくく運搬性に優れるので、生産性が良い。   The wet mat formed in this step has the back side on the lower side during transportation, but the skin layer on the back side has a high density, so that it is not easily deformed due to vibration and is excellent in transportability, so that the productivity is good.
本発明によれば、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有する鉱物質繊維板が得られる。   ADVANTAGE OF THE INVENTION According to this invention, while having the layer of the gradient density which becomes a low density toward a core part from a back surface, the mineral fiber board which has a layer of the gradient density which becomes a high density toward a surface from a core part is obtained.
また、本発明による鉱物質繊維板は裏面側の表皮層も表面側の表皮層も高密度であり、所定の強度を有するので、取扱性が良いだけでなく、成形性,表面性がよいので、表面あるいは裏面にロール等でピン孔加工やエンボス模様を付けることができるとともに、化粧シートを貼着し、あるいは、塗装を施して化粧板を製造できる。また、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有しているので、全体として低密度となり、軽量で吸音性,断熱性に優れている。さらには鉱物質繊維と無機質軽量骨材が主成分なので不燃性を有する。   Further, the mineral fiber board according to the present invention has a high density in both the skin layer on the back side and the skin layer on the surface side, and has a predetermined strength, so that not only the handling property is good, but also the moldability and surface property are good. The front or back surface can be pinned or embossed with a roll or the like, and a decorative sheet can be attached or painted to produce a decorative board. In addition, it has a gradient density layer that decreases in density from the back to the core and a gradient density layer that increases in density from the core to the surface. Excellent sound absorption and heat insulation. Furthermore, it is nonflammable because mineral fibers and inorganic lightweight aggregates are the main components.
本発明にかかる別の鉱物質繊維板の製造方法は、鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、凝集剤とともに水に投入,混合し、フロックが生じたスラリーを円網式抄造機の上流側に供給する工程と、その一方で、鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、凝集剤とともに水に投入,混合し、フロックが生じたスラリーを円網式抄造機の下流側に供給する工程と、前記各スラリーをフォーミングドラムを介して上流側から下流側に沿って連続で湿式抄造することにより、裏面から表面に向かって低密度となる傾斜密度を有したウェットマットを形成後にプレスを施し乾燥する工程とを有し、前記スラリーを円網式抄造機の上流側及び下流側に供給する工程では、前記無機質軽量骨材を35〜50重量%添加しかつ凝集剤を0.45〜2.0重量%添加することで、該スラリーを、前記ウェットマットの形成工程で湿式抄造により裏面から表面に向かって低密度となる傾斜密度の層を有するウェットマットを形成できる程度の大きさのフロックが生じたスラリーとする。 Another method for producing a mineral fiberboard according to the present invention is based on mineral fiber, inorganic lightweight aggregate, and binder, and is put into water together with a flocculant and mixed, and a slurry in which flocs are generated is a circular mesh type. The process of supplying the paper machine upstream, while the mineral fiber, inorganic lightweight aggregate, and binder are the main components. A step of supplying the slurry to the downstream side of the papermaking machine, and by continuously wet-making the respective slurries from the upstream side to the downstream side via the forming drum, has a gradient density that decreases from the back surface to the surface. Forming a wet mat and then drying it, and in the step of supplying the slurry to the upstream side and downstream side of the circular net-type paper machine, 35-50% by weight of the inorganic lightweight aggregate is added. And flocculant By adding .45~2.0 wt%, the slurry, enough to form a wet mat having a layer of gradient density becomes lower density toward the surface from the back by a wet paper making in the step of forming the wet mat The slurry is a floc of size.
本製造方法による鉱物質繊維板は、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有し、かつ、平均密度が0.10〜0.30g/cmである。 The mineral fiber board according to the present manufacturing method has a gradient density layer that decreases in density from the back surface toward the core portion, a gradient density layer that increases in density from the core portion toward the surface, and The average density is 0.10 to 0.30 g / cm 3 .
本発明によれば、前述の効果に加え、裏面から芯部へ向かって低密度となる傾斜密度の層と、残る芯部から表面へ向かって高密度となる傾斜密度の層とが、同じかあるいは異なる成分組成の鉱物質繊維板が得られる。このため、適材適所の成分組成となり、より一層軽量で吸音性,断熱性,取扱性に優れた鉱物質繊維が得られるという効果がある。   According to the present invention, in addition to the above-described effects, is the gradient density layer that decreases in density from the back surface toward the core portion and the gradient density layer that increases in density from the remaining core portion toward the surface the same? Or the mineral fiber board of a different component composition is obtained. For this reason, it has the effect that it becomes a component composition of the right material at the right place, and it is possible to obtain a mineral fiber that is much lighter and has excellent sound absorption, heat insulation and handling properties.
本発明にかかる実施形態を図1の添付図面に従って説明する。   An embodiment according to the present invention will be described with reference to the attached drawing of FIG.
本実施形態にかかる鉱物質繊維板は、鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有し、かつ、平均密度が0.10〜0.30g/cmである。 The mineral fiber board according to the present embodiment is mainly composed of mineral fibers, inorganic lightweight aggregates, and a binder, and has a gradient density layer having a low density from the back surface toward the core, and from the core to the surface. The layer has a gradient density that becomes higher toward the surface, and the average density is 0.10 to 0.30 g / cm 3 .
裏面から芯部に向かって低密度となる傾斜密度の層と芯部から表面に向かって高密度となる傾斜密度の層は、芯部において連続しており、2つの層として明確な境界があるものではなく、また、均等に分割できるものでもない。換言すれば、芯部から表裏面に向かって高密度となる傾斜密度を有している鉱物質繊維板である。芯部の層も他の層と明確な境界があるものではなく連続しているが、概ね鉱物質繊維板の中心部を示し、その密度は0.05〜0.20g/cm程度である。 The gradient density layer that decreases in density from the back to the core and the gradient density layer that increases in density from the core to the surface are continuous in the core, and there is a clear boundary between the two layers. It is not something that can be divided equally. In other words, the mineral fiber board has a gradient density that increases from the core portion toward the front and back surfaces. The core layer is continuous with other layers without any clear boundary, but generally indicates the center of the mineral fiberboard, and its density is about 0.05 to 0.20 g / cm 3. .
本実施形態にかかる鉱物質繊維板の平均密度は0.10〜0.30g/cmとしている。0.10g/cmより低いと所望の強度が得られなくなるからであり、また、0.30g/cmを超えると高い断熱性能や吸音性能が得られなくなるからである。 The average density of the mineral fiber board according to the present embodiment is set to 0.10 to 0.30 g / cm 3 . This is because if it is lower than 0.10 g / cm 3 , desired strength cannot be obtained, and if it exceeds 0.30 g / cm 3 , high heat insulation performance and sound absorption performance cannot be obtained.
また、本発明にかかる実施形態としては、裏面側の表皮層の密度を0.15〜0.80g/cmとしてもよい。密度が0.15g/cmよりも低いと所望の強度が得られず、残る裏面から芯部に向かって低密度となる傾斜密度の層と芯部から表面に向かって高密度となる傾斜密度の層を支持できなくなる。密度が0.80g/cmを超えると脱水性(濾水性)に劣り、生産性が著しく低下する。 Moreover, as embodiment concerning this invention, it is good also considering the density of the skin layer of a back surface side as 0.15-0.80 g / cm < 3 >. If the density is lower than 0.15 g / cm 3 , a desired strength cannot be obtained, and a gradient density layer in which the density decreases from the remaining back surface toward the core and a gradient density in which the density increases from the core to the surface. It becomes impossible to support the layer. When the density exceeds 0.80 g / cm 3 , the dehydrating property (drainage) is inferior, and the productivity is remarkably lowered.
なお、表皮層とは裏面側あるいは表面側の最も外側に位置する箇所の層を示すが、他の層と明確な境界があるものではなく、裏面から芯部に向かって低密度となる傾斜密度の層や、芯部から表面に向かって高密度となる傾斜密度の層とは連続して存在している。   The skin layer refers to the outermost layer on the back side or the front side, but there is no clear boundary with other layers, and the gradient density decreases from the back side toward the core. These layers and the gradient density layer that increases in density from the core toward the surface are continuously present.
本発明にかかる別の実施形態としては、裏面から芯部へ向かって低密度となる傾斜密度を有する層と、残る芯部から表面へ向かって高密度となる傾斜密度を有する層とを異なる成分組成で形成してもよい。   As another embodiment according to the present invention, a component having a gradient density that decreases in density from the back surface toward the core and a layer having a gradient density that increases in density from the remaining core toward the surface are different components. You may form with a composition.
本実施形態によれば、適材適所の成分組成となるので、より軽量で吸音性,断熱性,取扱性に優れた鉱物質繊維が得られる。   According to this embodiment, since the component composition of the appropriate material is the right place, a mineral fiber that is lighter in weight, excellent in sound absorption, heat insulation, and handleability can be obtained.
さらに、本発明の鉱物質繊維板を複数枚貼り合わせて一体化した鉱物質繊維板であってもよい。   Furthermore, the mineral fiber board which stuck together and integrated the multiple mineral fiber board of this invention may be sufficient.
この実施形態によれば、所望の厚さの鉱物質繊維板が得られるだけでなく、表裏面側の表皮層と芯部の層が高密度となり、他の層が低密度となるので、吸音性,断熱性,取扱性により優れた鉱物質繊維が得られる。   According to this embodiment, not only a mineral fiber board with a desired thickness can be obtained, but also the skin layer and the core layer on the front and back sides have a high density, and the other layers have a low density. Excellent mineral fiber due to its properties, heat insulation, and handleability.
鉱物質繊維としては、例えばロックウール、スラグウール、グラスウール等が挙げられる。また、鉱物質繊維の添加量は、スラリー固形成分中の25〜85重量%(25重量%以上でかつ85重量%以下)が好ましい。25重量%未満であると、抄造して得られるウェットマットの嵩が低いからであり、85重量%を超えると、相対的に無機質軽量骨材の添加量に制限が加わり、所定の軽量性が得にくくなるからである。   Examples of mineral fibers include rock wool, slag wool, and glass wool. Moreover, the addition amount of the mineral fiber is preferably 25 to 85% by weight (25% by weight or more and 85% by weight or less) in the slurry solid component. If it is less than 25% by weight, the volume of the wet mat obtained by papermaking is low. If it exceeds 85% by weight, the amount of the inorganic lightweight aggregate is relatively limited, and a predetermined light weight is obtained. This is because it becomes difficult to obtain.
無機質軽量骨材としては、例えば、パーライト、シラスバルーン等の無機質発泡体が挙げられる。また、鉱物質繊維のダマ(繊維の毛玉状小粒)を利用してもよい。さらに、クレー、炭酸カルシウム、水酸化アルミニウム、珪砂、スラグ、ガラス粉等の無機質非発泡体由来の軽量造粒物であってもよい。   Examples of the inorganic lightweight aggregate include inorganic foams such as perlite and shirasu balloon. Alternatively, mineral fiber dama (fiber pill-like granules) may be used. Further, it may be a light-weight granulated material derived from an inorganic non-foamed material such as clay, calcium carbonate, aluminum hydroxide, silica sand, slag, and glass powder.
そして、無機質軽量骨材の添加量はスラリー固形成分の35〜50重量%(35重量%以上でかつ50重量%以下)が好ましい。35重量%未満であると、表面平滑性が得られないからであり、50重量%を超えると、相対的に鉱物質繊維の添加量が減少し、十分な強度が発現できないとともに、抄造時の脱水性(濾水性)が著しく低下し、生産性が低下するためである。 And the addition amount of an inorganic lightweight aggregate is 35 to 50 weight% ( 35 weight% or more and 50 weight% or less) of a slurry solid component. If the amount is less than 35 % by weight, the surface smoothness cannot be obtained. If the amount exceeds 50% by weight, the amount of mineral fibers is relatively reduced, and sufficient strength cannot be exhibited. This is because the dehydrating property (drainage) is remarkably lowered and the productivity is lowered.
結合剤は、固形成分を結合して板状体を形成するためのものであり、例えばデンプン、PVA、フェノール、メラミン、アクリル、エポキシ、ウレタン、酢酸ビニル系の樹脂等が挙げられ、添加量は2〜18重量%(2重量%以上でかつ18重量%以下)が好ましい。2重量%未満であると、所望の強度が得られないからであり、18重量%を超えると、防火性が失われるからである。   The binder is for binding a solid component to form a plate-like body, and examples thereof include starch, PVA, phenol, melamine, acrylic, epoxy, urethane, vinyl acetate resin, and the addition amount is It is preferably 2 to 18% by weight (2% by weight or more and 18% by weight or less). This is because if it is less than 2% by weight, the desired strength cannot be obtained, and if it exceeds 18% by weight, fire resistance is lost.
凝集剤としては、例えば、ポリアクリルアミド、ポリアクリルアミド変性物、PAC(ポリ塩化アルミニウム)、硫酸バンド(硫酸アルミニウム)等であり、より多くの無機質粉体を鉱物質繊維に定着させるためには高粘度で高分子のものが望ましい。   Examples of the aggregating agent include polyacrylamide, polyacrylamide-modified product, PAC (polyaluminum chloride), and sulfuric acid band (aluminum sulfate). High viscosity is required to fix more inorganic powders on mineral fibers. And high molecular weight is desirable.
そして、凝集剤の添加量は0.45〜2.0重量%(0.45重量%以上でかつ2.0重量%以下)が好ましい。0.45重量%未満であると、凝集力が低く、目視で大きなフロックが得にくくなり、傾斜密度を実現することが困難になるからである。2.0重量%を超えるとフロックが大きくなりすぎ、表面性等の地合の制御が困難になり、強度にバラツキが生じやすくなるからである。なお、凝集剤に適した水質にpH調整をすると、フロック形成に良好に作用する場合がある。 The addition amount of the flocculant is preferably 0.45 to 2.0% by weight ( 0.45 % by weight or more and 2.0% by weight or less). If it is less than 0.45 % by weight, the cohesive force is low, it is difficult to obtain a large floc by visual observation, and it becomes difficult to realize a gradient density. If the content exceeds 2.0% by weight, the floc becomes too large, and it becomes difficult to control the surface properties and the like, and the strength tends to vary. In addition, if the pH is adjusted to a water quality suitable for the flocculant, it may work well for floc formation.
また、必要に応じ、強度向上のために古紙、ガラス繊維、粘土鉱物や、水ガラス、セメント系の無機バインダー等を適宜添加してもよい。   If necessary, waste paper, glass fibers, clay minerals, water glass, cement-based inorganic binders, and the like may be added as appropriate to improve strength.
なお、フロックとは、主成分である多数の繊維の表面に凝集剤を介して結合剤,軽量骨材が付着してできた集合体をいう。   In addition, a floc means the aggregate | assembly which the binder and the lightweight aggregate adhered to the surface of many fibers which are main components through a flocculant.
そして、目視で大きいとは、湿式抄造方式で鉱物質繊維板を製造する当業者が、通常の原材料でスラリーとした場合において得られるフロックよりも大きいものをいう。具体的には、スラリーは、湿式抄造により裏面から表面に向かって低密度となる傾斜密度の層を有するウェットマットを形成できる程度の大きさのフロックが生じたスラリーである。   And it is larger than the floc obtained when a person skilled in the art that manufactures mineral fiber board by a wet papermaking method uses a normal raw material as a slurry. Specifically, the slurry is a slurry in which a floc having a size enough to form a wet mat having a gradient density layer that decreases in density from the back surface to the front surface by wet papermaking.
前述の材料からなるスラリーを抄造する方法としては、例えば、図1Aに示すように、円網式抄造機において、鉱物質繊維等を水に投入,混合して目視で大きなフロック2が生じたスラリー1を、ヘッドボックス10を介してスラリー槽11に投入する。そして、フォーミングドラム12を回転させて抄造すると、最初に前記目視で大きなフロック2が前記フォーミングドラム12に吸い寄せられて積層し、強く吸引されて高密度の裏面側の表皮層3を形成した後、さらに目視で大きなフロック2が吸い寄せられて付着積層する。そして、フォーミングドラム12の回転が進み、目視で大きなフロック2が付着すればする程、吸引力が低下していくので、目視で大きなフロック2の付着量が徐々に減少し、裏面から表面に向かって低密度となる傾斜密度の層4を有するウェットマット5が形成される。その後、ウェットマット5をブラッシロール14やプレスロール15で表面を平滑に、かつ、厚さを整えながらプレスする。ウェットマット5は密度に応じてプレス圧力の影響を受け、特に密度の低い表面側の密度が変化する。そして、乾燥機で加熱,乾燥することにより、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有する鉱物質繊維板が得られる。尚、工程上において乾燥機の前に、脱水、固着化や厚さの微調整の為、バキュームでの吸引、熱風乾燥、プレスロール等を加えて、表面や厚さを整えることも生産性上好ましい。   For example, as shown in FIG. 1A, a slurry in which a large floc 2 is generated visually by adding and mixing mineral fibers into water in a circular mesh paper machine as shown in FIG. 1A. 1 is put into the slurry tank 11 through the head box 10. Then, when the forming drum 12 is rotated to make paper, first, the large floc 2 is visually attracted to the forming drum 12 and stacked, and then strongly sucked to form the skin layer 3 on the back surface side having a high density. Further, a large floc 2 is sucked and visually laminated. Then, as the forming drum 12 is further rotated and the larger the flocs 2 are visually attached, the suction force is reduced. Therefore, the amount of the larger flocks 2 is visually reduced and gradually increases from the back surface to the surface. Thus, the wet mat 5 having the gradient density layer 4 having a low density is formed. Thereafter, the wet mat 5 is pressed with a brush roll 14 or a press roll 15 while smoothing the surface and adjusting the thickness. The wet mat 5 is affected by the press pressure depending on the density, and the density on the surface side having a particularly low density changes. And it has a graded density layer that becomes low density from the back to the core by heating and drying with a dryer, and a mineral substance that has a graded density layer that becomes high density from the core to the surface. A fiberboard is obtained. In addition, it is also possible to adjust the surface and thickness by adding vacuum suction, hot air drying, press roll, etc. for dehydration, fixation and fine adjustment of thickness before the dryer in the process. preferable.
また、他の抄造方法としては、例えば、図1Bに示すように、同一の円網式抄造機の上流側に目視で大きなフロック2’が生じたスラリー6を上流タンク13を介して供給する一方、その下流側に前述のスラリー6と同一成分組成、あるいは、異なる成分組成の目視で大きなフロック2’あるいは目視で大きなフロック2が生じたスラリー1をヘッドボックス10を介して供給する。そして、フォーミングドラム12を介して上流側から下流側に沿って連続で湿式抄造することにより、高密度の裏面側の表皮層3と、裏面から表面に向かって低密度となる傾斜密度の層4とからなるウェットマット5を抄造してもよい。その後、ウェットマット5をブラッシロール14やプレスロール15で表面を平滑に、かつ、厚さを整えながらプレスする。そして、乾燥機で加熱,乾燥することにより、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有する鉱物質繊維板が得られる。尚、工程上において乾燥機の前に、脱水、固着化や厚さの微調整の為、バキュームでの吸引、熱風乾燥、プレスロール等を加えて、表面や厚さを整えることも生産性上好ましい。   Further, as another papermaking method, for example, as shown in FIG. 1B, a slurry 6 in which a large floc 2 'is visually generated on the upstream side of the same circular netting machine is supplied via an upstream tank 13. The slurry 1 having the same component composition as that of the slurry 6 or a component composition different from that of the slurry 6 in which a large floc 2 ′ or a large floc 2 is visually observed is supplied via the head box 10. Then, by continuously wet-making from the upstream side to the downstream side via the forming drum 12, the skin layer 3 on the back surface side having a high density, and the layer 4 having a gradient density that decreases in density from the back surface to the surface. A wet mat 5 comprising: Thereafter, the wet mat 5 is pressed with a brush roll 14 or a press roll 15 while smoothing the surface and adjusting the thickness. And it has a graded density layer that becomes low density from the back to the core by heating and drying with a dryer, and a mineral substance that has a graded density layer that becomes high density from the core to the surface. A fiberboard is obtained. In addition, it is also possible to adjust the surface and thickness by adding vacuum suction, hot air drying, press roll, etc. for dehydration, fixation and fine adjustment of thickness before the dryer in the process. preferable.
(実施例1)
鉱物質繊維としてロックウール55重量部、無機質軽量骨材として粒径1μm〜2mmのパーライト35重量部、結合剤としてデンプン8重量部、凝集剤としてポリ塩化アルミニウム0.25重量部、ポリアクリルアミド0.2重量部、その他添加剤として撥水剤0.1重量部を、水中に投入し、攪拌,混合,分散させて固形成分1.2%のスラリーを得た。前記スラリー中に目視で大きなフロックの存在を確認できた。
Example 1
Rock wool as mineral fiber 55 parts by weight, inorganic lightweight aggregate 35 parts by weight of pearlite having a particle size of 1 μm to 2 mm, starch 8 parts by weight, flocculant 0.25 parts by weight polyaluminum chloride, polyacrylamide 0. 2 parts by weight and 0.1 part by weight of a water repellent as other additives were put into water, stirred, mixed and dispersed to obtain a slurry having a solid content of 1.2%. The presence of large flocs was visually confirmed in the slurry.
前記スラリーを円網式抄造機で抄造したところ、抄造初期はフォーミングドラムの網にフロックが多数付着し、密度の高い裏面側の表皮層が形成された。さらに、フォーミングドラムを回転させて抄造することにより、徐々にフロックの付着が減少し、抄造後期ではフロックの付着量が少なくなり、裏面から表面に向かって低密度となるように傾斜した層を有するウェットマットが得られた。   When the slurry was made with a circular net-type machine, many flocs adhered to the forming drum net in the initial stage of the paper making, and a dense skin layer on the back side was formed. Furthermore, by rotating the forming drum and making paper, the adhesion of flocs gradually decreases, and the amount of floc adhesion decreases in the late stage of paper making, and it has a layer that is inclined so that the density decreases from the back to the surface. A wet mat was obtained.
抄造された前記ウェットマットをブラッシロールやプレスロールで表面を平滑に、かつ、厚さを整えながらプレスし、更に脱水と固着化の為にバキュームで吸引させながら150℃の熱風を当て、厚さの微調整の為にプレスロールに通した後、ドライヤーで乾燥させ、裏面側の表皮層の密度が0.52g/cmで裏面から芯部に向かって低密度となる傾斜密度を有するとともに、芯部から表面に向かって高密度となる傾斜密度を有し、表面側の表皮層の密度が0.43g/cmで全体の平均密度が0.18g/cmの鉱物質繊維板を得、これをサンプルとし、各種の測定、特性試験を行った。説明の便宜上、実施例の組成表および各種試験結果の表を図2A,2Bにそれぞれ示す。また、断面位置における密度変化を図4Aに示す。 The paper-made wet mat is pressed with a brush roll or a press roll while smoothing the surface and adjusting the thickness, and then heated with 150 ° C hot air while vacuuming for dehydration and fixation. After passing through a press roll for fine adjustment of the above, it is dried with a dryer, and the density of the skin layer on the back surface side is 0.52 g / cm 3 and has a gradient density that decreases from the back surface toward the core, A mineral fiber board having a gradient density increasing from the core toward the surface, a density of the skin layer on the surface side of 0.43 g / cm 3 and an overall average density of 0.18 g / cm 3 is obtained. Using this as a sample, various measurements and characteristic tests were performed. For convenience of explanation, a composition table of Examples and tables of various test results are shown in FIGS. 2A and 2B, respectively. Moreover, the density change in the cross-sectional position is shown in FIG. 4A.
(実施例2)
鉱物質繊維としてロックウール55重量部、無機質軽量骨材として粒径1μm〜2mmのパーライト35重量部、結合剤としてデンプン8重量部、凝集剤としてポリ塩化アルミニウム0.25重量部、ポリアクリルアミド0.24重量部、その他添加剤として撥水剤0.1重量部を、水中に投入し、攪拌,混合,分散させて固形成分1.2%のスラリーを得た。前記スラリー中に目視で大きなフロックの存在を確認できた。
(Example 2)
Rock wool as mineral fiber 55 parts by weight, inorganic lightweight aggregate 35 parts by weight of pearlite having a particle size of 1 μm to 2 mm, starch 8 parts by weight, flocculant 0.25 parts by weight polyaluminum chloride, polyacrylamide 0. 24 parts by weight and 0.1 part by weight of a water repellent as other additives were put into water and stirred, mixed, and dispersed to obtain a slurry having a solid content of 1.2%. The presence of large flocs was visually confirmed in the slurry.
前記スラリーを円網式抄造機で抄造したところ、抄造初期はフォーミングドラムの網にフロックが多数付着し、密度の高い裏面側の表皮層が形成された。さらに、フォーミングドラムを回転させて抄造することにより、徐々にフロックの付着が減少し、抄造後期ではフロックの付着量が少なくなり、裏面から表面に向かって低密度となるように傾斜した層を有するウェットマットが得られた。   When the slurry was made with a circular net-type machine, many flocs adhered to the forming drum net in the initial stage of the paper making, and a dense skin layer on the back side was formed. Furthermore, by rotating the forming drum and making paper, the adhesion of flocs gradually decreases, and the amount of floc adhesion decreases in the late stage of paper making, and it has a layer that is inclined so that the density decreases from the back to the surface. A wet mat was obtained.
抄造された前記ウェットマットをブラッシロールやプレスロールで表面を平滑に、かつ、厚さを整えながらプレスし、更に脱水と固着化の為にバキュームで吸引させながら150℃の熱風を当て、厚さの微調整の為にプレスロールに通した後、ドライヤーで乾燥させ、裏面側の表皮層の密度が0.39g/cmで裏面から芯部に向かって低密度となる傾斜密度を有するとともに、芯部から表面に向かって高密度となる傾斜密度を有し、表面側の表皮層の密度が0.31g/cmで全体の平均密度が0.17g/cmの鉱物質繊維板を得、これをサンプルとし、各種の測定、特性試験を行った。説明の便宜上、実施例の組成表および各種試験結果の表を図2A,2Bにそれぞれ示す。また、断面位置における密度変化を図4Bに示す。 The paper-made wet mat is pressed with a brush roll or a press roll while smoothing the surface and adjusting the thickness, and then heated with 150 ° C hot air while vacuuming for dehydration and fixation. After passing through a press roll for fine adjustment of the above, it is dried with a dryer, and the density of the skin layer on the back surface side is 0.39 g / cm 3 and has a gradient density that decreases from the back surface toward the core, A mineral fiber board having a gradient density that increases from the core toward the surface, a density of the skin layer on the surface side of 0.31 g / cm 3 , and an overall average density of 0.17 g / cm 3 is obtained. Using this as a sample, various measurements and characteristic tests were performed. For convenience of explanation, a composition table of Examples and tables of various test results are shown in FIGS. 2A and 2B, respectively. Moreover, the density change in a cross-sectional position is shown in FIG. 4B.
(実施例3)
鉱物質繊維としてロックウール55重量部、無機質軽量骨材として粒径1μm〜2mmのパーライト35重量部、結合剤としてデンプン8重量部、凝集剤としてポリ塩化アルミニウム0.25重量部、ポリアクリルアミド0.3重量部、その他添加剤として撥水剤0.1重量部を、水中に投入し、攪拌,混合,分散させて固形成分1.2%のスラリーを得た。前記スラリー中に目視で大きなフロックの存在を確認できた。
(Example 3)
Rock wool as mineral fiber 55 parts by weight, inorganic lightweight aggregate 35 parts by weight of pearlite having a particle size of 1 μm to 2 mm, starch 8 parts by weight, flocculant 0.25 parts by weight polyaluminum chloride, polyacrylamide 0. 3 parts by weight and 0.1 part by weight of a water repellent as other additives were put into water and stirred, mixed, and dispersed to obtain a slurry having a solid content of 1.2%. The presence of large flocs was visually confirmed in the slurry.
前記スラリーを円網式抄造機で抄造したところ、抄造初期はフォーミングドラムの網にフロックが多数付着し、密度の高い裏面側の表皮層が形成された。さらに、フォーミングドラムを回転させて抄造することにより、徐々にフロックの付着が減少し、抄造後期ではフロックの付着量が少なくなり、裏面から表面に向かって低密度となるように傾斜した層を有するウェットマットが得られた。   When the slurry was made with a circular net-type machine, many flocs adhered to the forming drum net in the initial stage of the paper making, and a dense skin layer on the back side was formed. Furthermore, by rotating the forming drum and making paper, the adhesion of flocs gradually decreases, and the amount of floc adhesion decreases in the late stage of paper making, and it has a layer that is inclined so that the density decreases from the back to the surface. A wet mat was obtained.
抄造された前記ウェットマットをブラッシロールやプレスロールで表面を平滑に、かつ、厚さを整えながらプレスし、更に脱水と固着化の為にバキュームで吸引させながら150℃の熱風を当て、厚さの微調整の為にプレスロールに通した後、ドライヤーで乾燥させ、裏面側の表皮層の密度が0.40g/cmで裏面から芯部に向かって低密度となる傾斜密度を有するとともに、芯部から表面に向かって高密度となる傾斜密度を有し、表面側の表皮層の密度が0.29g/cmで全体の平均密度が0.17g/cmの鉱物質繊維板を得、これをサンプルとし、各種の測定、特性試験を行った。説明の便宜上、実施例の組成表および各種試験結果の表を図2A,2Bにそれぞれ示す。また、断面位置における密度変化を図5Cに示す。 The paper-made wet mat is pressed with a brush roll or a press roll while smoothing the surface and adjusting the thickness, and then heated with 150 ° C hot air while vacuuming for dehydration and fixation. After passing through a press roll for fine adjustment of the above, it is dried with a dryer, and the density of the skin layer on the back surface side is 0.40 g / cm 3 and has a gradient density that decreases from the back surface toward the core, A mineral fiber board having a gradient density that increases from the core toward the surface, having a skin layer density of 0.29 g / cm 3 on the surface side and an overall average density of 0.17 g / cm 3 is obtained. Using this as a sample, various measurements and characteristic tests were performed. For convenience of explanation, a composition table of Examples and tables of various test results are shown in FIGS. 2A and 2B, respectively. Moreover, the density change in the cross-sectional position is shown in FIG. 5C.
(実施例4)
鉱物質繊維としてロックウール55重量部、無機質軽量骨材として粒径1μm〜2mmのパーライト35重量部、結合剤としてデンプン8重量部、凝集剤としてポリ塩化アルミニウム0.25重量部、ポリアクリルアミド0.40重量部、その他添加剤として撥水剤0.1重量部を、水中に投入し、攪拌,混合,分散させて固形成分1.2%のスラリーを得た。前記スラリー中に目視で大きなフロックの存在を確認できた。
Example 4
Rock wool as mineral fiber 55 parts by weight, inorganic lightweight aggregate 35 parts by weight of pearlite having a particle size of 1 μm to 2 mm, starch 8 parts by weight, flocculant 0.25 parts by weight polyaluminum chloride, polyacrylamide 0. 40 parts by weight and 0.1 part by weight of a water repellent as other additives were put into water and stirred, mixed, and dispersed to obtain a slurry having a solid content of 1.2%. The presence of large flocs was visually confirmed in the slurry.
前記スラリーを円網式抄造機で抄造したところ、抄造初期はフォーミングドラムの網にフロックが多数付着し、密度の高い裏面側の表皮層が形成された。さらに、フォーミングドラムを回転させて抄造することにより、徐々にフロックの付着が減少し、抄造後期ではフロックの付着量が少なくなり、裏面から表面に向かって低密度となるように傾斜した層を有するウェットマットが得られた。   When the slurry was made with a circular net-type machine, many flocs adhered to the forming drum net in the initial stage of the paper making, and a dense skin layer on the back side was formed. Furthermore, by rotating the forming drum and making paper, the adhesion of flocs gradually decreases, and the amount of floc adhesion decreases in the late stage of paper making, and it has a layer that is inclined so that the density decreases from the back to the surface. A wet mat was obtained.
抄造された前記ウェットマットをブラッシロールやプレスロールで表面を平滑に、かつ、厚さを整えながらプレスし、更に脱水と固着化の為にバキュームで吸引させながら150℃の熱風を当て、厚さの微調整の為にプレスロールに通した後、ドライヤーで乾燥させ、裏面側の表皮層の密度が0.40g/cmで裏面から芯部に向かって低密度となる傾斜密度を有するとともに、芯部から表面に向かって高密度となる傾斜密度を有し、表面側の表皮層の密度が0.28g/cmで全体の平均密度が0.16g/cmの鉱物質繊維板を得、これをサンプルとし、各種の測定、特性試験を行った。吸音率はASTM C423に準じて測定している。説明の便宜上、実施例の組成表および各種試験結果の表を図2A,2Bにそれぞれ示す。また、断面位置における密度変化を図5Dに、周波数毎の吸音率を図7Aに示す。 The paper-made wet mat is pressed with a brush roll or a press roll while smoothing the surface and adjusting the thickness, and then heated with 150 ° C hot air while vacuuming for dehydration and fixation. After passing through a press roll for fine adjustment of the above, it is dried with a dryer, and the density of the skin layer on the back surface side is 0.40 g / cm 3 and has a gradient density that decreases from the back surface toward the core, an inclined density becomes dense toward the surface from the core, the surface side of the resulting mineral fiberboard of average density of the entire density of the skin layer is at 0.28 g / cm 3 is 0.16 g / cm 3 Using this as a sample, various measurements and characteristic tests were performed. The sound absorption rate is measured according to ASTM C423. For convenience of explanation, a composition table of Examples and tables of various test results are shown in FIGS. 2A and 2B, respectively. Moreover, the density change in a cross-sectional position is shown in FIG. 5D, and the sound absorption rate for each frequency is shown in FIG. 7A.
(比較例1)
鉱物質繊維としてロックウール80重量部、無機質軽量骨材として粒径1μm〜2mmのパーライト8重量部、結合剤としてデンプン5重量部、増量剤としてクレー7重量部、凝集剤として硫酸アルミニウム0.1重量部、ポリアクリルアミド0.2重量部、その他添加剤として撥水剤0.1重量部を、水中に投入し、攪拌,混合,分散させて固形成分1.2%のスラリーを得た。ただし、前記スラリー中にフロックは存在するが、実施例のような目視で大きなフロックの存在は確認できなかった。
(Comparative Example 1)
80 parts by weight of rock wool as mineral fiber, 8 parts by weight of pearlite having a particle size of 1 μm to 2 mm as inorganic lightweight aggregate, 5 parts by weight of starch as binder, 7 parts by weight of clay as bulking agent, 0.1% of aluminum sulfate as flocculant Part by weight, 0.2 part by weight of polyacrylamide, and 0.1 part by weight of a water repellent as other additives were put into water, stirred, mixed, and dispersed to obtain a slurry having a solid content of 1.2%. However, although flocs exist in the slurry, the presence of large flocs was not confirmed visually as in the examples.
前記スラリーを円網式抄造機のフォーミングドラムで抄造し、得られたウェットマットを実施例1と同様に処理することにより、平均密度0.31g/cmの鉱物質繊維板を得、これをサンプルとして各種の測定,特性試験を行った。吸音率はASTM C423に準じて測定している。比較例の組成表および各種試験結果表を図2A,2Bにそれぞれ示す。また、断面位置における密度変化を図6Eに、周波数毎の吸音率を図7Bに示す。 The slurry was made with a forming drum of a net-type paper making machine, and the resulting wet mat was treated in the same manner as in Example 1 to obtain a mineral fiber board having an average density of 0.31 g / cm 3. Various measurements and characteristic tests were performed as samples. The sound absorption rate is measured according to ASTM C423. A composition table and various test result tables of the comparative examples are shown in FIGS. 2A and 2B, respectively. Further, FIG. 6E shows the density change at the cross-sectional position, and FIG. 7B shows the sound absorption coefficient for each frequency.
(比較例2)
鉱物質繊維としてロックウール75重量部、無機質軽量骨材として粒径1μm〜2mmのパーライト8重量部、結合剤としてデンプン5重量部、増量剤としてクレー7重量部、古紙5重量部、凝集剤として硫酸アルミニウム0.1重量部、ポリアクリルアミド0.2重量部、その他添加剤として撥水剤0.1重量部を、水中に投入し、攪拌,混合,分散させて固形成分1.2%のスラリーを得た。ただし、前記スラリー中にフロックは存在するが、実施例のような目視で大きなフロックの存在は確認できなかった。
(Comparative Example 2)
75 parts by weight of rock wool as mineral fiber, 8 parts by weight of pearlite with a particle size of 1 μm to 2 mm as inorganic lightweight aggregate, 5 parts by weight of starch as binder, 7 parts by weight of clay as extender, 5 parts by weight of waste paper, as flocculant 0.1 part by weight of aluminum sulfate, 0.2 part by weight of polyacrylamide, and 0.1 part by weight of water repellent as an additive are put into water, stirred, mixed and dispersed to give a slurry of 1.2% solid component Got. However, although flocs exist in the slurry, the presence of large flocs was not confirmed visually as in the examples.
前記スラリーを円網式抄造機のフォーミングドラムで抄造し、得られたウェットマットを実施例1と同様に処理することにより、平均密度0.33g/cmの鉱物質繊維板を得、これをサンプルとして各種の測定,特性試験を行った。比較例の組成表および各種試験結果表を図2A,2Bにそれぞれ示す。また、断面位置における密度変化を図6Fに示す。 The slurry was made with a forming drum of a net-type paper making machine, and the resulting wet mat was treated in the same manner as in Example 1 to obtain a mineral fiber board having an average density of 0.33 g / cm 3. Various measurements and characteristic tests were performed as samples. A composition table and various test result tables of the comparative examples are shown in FIGS. 2A and 2B, respectively. Moreover, the density change in the cross-sectional position is shown in FIG. 6F.
図4、図5から明らかなように、実施例1〜4は裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有することが判った。平均密度も低密度であることが確認された。   As is clear from FIGS. 4 and 5, Examples 1 to 4 have a gradient density layer having a low density from the back surface toward the core, and a gradient density having a high density from the core to the surface. It was found to have a layer. It was confirmed that the average density was also low.
また、図7から明らかなように、吸音率において実施例4の方が比較例1よりも各周波数帯において優れた吸音性を有していることが判った。   Further, as apparent from FIG. 7, it was found that the sound absorption rate of Example 4 was superior to that of Comparative Example 1 in each frequency band.
さらに、図2の試験結果表から明らかなように、実施例4の方が比較例1よりも熱伝導率が小さく、断熱性能が優れていることが判った。また、実施例1〜4の方が比較例1よりも曲げ強度および硬度において小さいが、施工等における実用上の問題がないことを確認できた。   Further, as is apparent from the test result table of FIG. 2, it was found that Example 4 had a lower thermal conductivity than that of Comparative Example 1, and had better heat insulation performance. Moreover, although the direction of Examples 1-4 was smaller in the bending strength and hardness than the comparative example 1, it has confirmed that there was no practical problem in construction etc.
本発明にかかる鉱物質繊維板は、単なる吸音板としてだけでなく、例えば、化粧板,断熱材としても使用できる。   The mineral fiber board according to the present invention can be used not only as a sound absorbing board but also as a decorative board and a heat insulating material, for example.
図1A,1Bは本発明にかかる鉱物質繊維板の抄造機を説明するための概略図である。1A and 1B are schematic views for explaining a mineral fiberboard papermaking machine according to the present invention. 図2A,2Bは実施例および比較例の組成及び試験結果を示す図表である。2A and 2B are charts showing compositions and test results of Examples and Comparative Examples. 図3は実施例1の傾斜密度を示すグラフ図とその説明である。FIG. 3 is a graph showing the gradient density of Example 1 and its explanation. 図4A,4Bは実施例1、2の傾斜密度を示すグラフ図である。4A and 4B are graphs showing the gradient density of Examples 1 and 2. FIG. 図5C,5Dは実施例3,4の傾斜密度を示すグラフ図である。5C and 5D are graphs showing the gradient density of Examples 3 and 4. FIG. 図6E,6Fは比較例1,2の傾斜密度を示すグラフ図である。6E and 6F are graphs showing the gradient density of Comparative Examples 1 and 2. FIG. 図7A,7Bは実施例4および比較例1の吸音率を示すグラフ図である。7A and 7B are graphs showing the sound absorption rates of Example 4 and Comparative Example 1. FIG.
1:スラリー(下流側)
2,2’:目視で大きなフロック
3:裏面側の表皮層
4:裏面から表面に向かって低密度となる傾斜密度の層
5:ウェットマット
6:スラリー(上流側)
10:ヘッドボックス
11:スラリー槽
12:フォーミングドラム
13:上流タンク
14:ブラッシロール
15:プレスロール
1: Slurry (downstream)
2, 2 ': Visually large floc 3: Skin layer 4 on the back side 4: Layer of gradient density that decreases from the back side to the surface 5: Wet mat 6: Slurry (upstream side)
10: Head box 11: Slurry tank 12: Forming drum 13: Upstream tank 14: Brush roll 15: Press roll

Claims (4)

  1. 鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、裏面から芯部に向かって低密度となる傾斜密度の層を有するとともに、芯部から表面に向かって高密度となる傾斜密度の層を有し、かつ、平均密度が0.10〜0.30g/cmであることを特徴とする鉱物質繊維板。 Mineral fiber, inorganic light-weight aggregate, and binder as main components, and having a gradient density layer that decreases in density from the back to the core, and a gradient density layer that increases in density from the core to the surface And a mineral fiber board characterized by having an average density of 0.10 to 0.30 g / cm 3 .
  2. 裏面から芯部に向かって低密度となる傾斜密度の層と芯部から表面に向かって高密度となる傾斜密度の層とが異なる成分組成で形成されていることを特徴とする請求項1に記載の鉱物質繊維板。   2. The gradient density layer having a low density from the back surface toward the core portion and the gradient density layer having a high density from the core portion to the surface are formed of different component compositions. Mineral fiberboard as described.
  3. 鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、凝集剤とともに水に投入,混合し、フロックが生じたスラリーとする工程と、
    前記スラリーを円網式抄造機で湿式抄造し、裏面から表面に向かって低密度となる傾斜密度を有したウェットマットを形成する工程と、
    前記ウェットマットにプレスを施し乾燥する工程とを有し、
    前記スラリーの生成工程では、前記無機質軽量骨材を35〜50重量%添加しかつ凝集剤を0.45〜2.0重量%添加することで、該スラリーを、前記ウェットマットの形成工程で湿式抄造により裏面から表面に向かって低密度となる傾斜密度の層を有するウェットマットを形成できる程度の大きさのフロックが生じたスラリーとする、請求項1に記載の鉱物質繊維板の製造方法。
    A process comprising a mineral fiber, an inorganic lightweight aggregate and a binder as main components, and a floc-generated slurry that is added to and mixed with water together with a flocculant;
    Wet-making the slurry with a circular net-making machine, forming a wet mat having a gradient density that decreases from the back to the surface;
    And applying a press to the wet mat and drying,
    In the slurry generation step, 35-50% by weight of the inorganic light-weight aggregate and 0.45-2.0% by weight of a flocculant are added, so that the slurry is wet in the wet mat forming step. The method for producing a mineral fiber board according to claim 1, wherein the slurry is a slurry in which flocs having a size capable of forming a wet mat having a gradient density layer having a lower density from the back surface to the front surface by papermaking.
  4. 鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、凝集剤とともに水に投入,混合し、フロックが生じたスラリーを円網式抄造機の上流側に供給する工程と、
    その一方で、鉱物質繊維と無機質軽量骨材と結合剤を主成分とし、凝集剤とともに水に投入,混合し、フロックが生じたスラリーを円網式抄造機の下流側に供給する工程と、
    前記各スラリーをフォーミングドラムを介して上流側から下流側に沿って連続で湿式抄造することにより、裏面から表面に向かって低密度となる傾斜密度を有したウェットマットを形成する工程と、
    前記ウェットマットにプレスを施し乾燥する工程とを有し、
    前記スラリーを円網式抄造機の上流側及び下流側に供給する工程では、前記無機質軽量骨材を35〜50重量%添加しかつ凝集剤を0.45〜2.0重量%添加することで、該スラリーを、前記ウェットマットの形成工程で湿式抄造により裏面から表面に向かって低密度となる傾斜密度の層を有するウェットマットを形成できる程度の大きさのフロックが生じたスラリーとする、請求項1または請求項2に記載の鉱物質繊維板の製造方法。
    A step of supplying mineral slurry, inorganic lightweight aggregate and binder as main components, adding and mixing flocculant into water, and supplying the floc-generated slurry to the upstream side of the circular net-making machine;
    On the other hand, a process comprising a mineral fiber, an inorganic light-weight aggregate and a binder as main components, and the flocculent is added to and mixed with water, and the floc-generated slurry is supplied to the downstream side of the circular net-making machine;
    Forming a wet mat having a gradient density that becomes a low density from the back surface to the surface by continuously wet-making paper from the upstream side to the downstream side through each forming slurry, and
    And applying a press to the wet mat and drying,
    In the step of supplying the slurry to the upstream side and the downstream side of the circular net-type paper machine, 35 to 50% by weight of the inorganic lightweight aggregate and 0.45 to 2.0% by weight of a flocculant are added. The slurry is a slurry in which flocs having a size sufficient to form a wet mat having a gradient density layer having a low density from the back surface to the front surface by wet papermaking in the wet mat forming step. The manufacturing method of the mineral fiber board of Claim 1 or Claim 2.
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