JP6716635B2 - Thin insulation board and manufacturing method thereof - Google Patents

Description

TECHNICAL FIELD The present invention relates to a curing material used for surface protection of completed parts such as stairs, walls, floors, columns, etc. of a building under construction or finally finished, and a method for producing the same, and particularly to a thin plate having a thickness of 3 to less than 6 mm. The present invention relates to a curing material using a thin insulation board and a manufacturing method thereof.

In construction and moving work, floors, pillars, stairs and other previously completed parts are covered with a curing material to protect them from ongoing work. As the curing material, hardboard, plywood, medium density fiberboard (MDF), corrugated board, or insulation board having a plate thickness of 6 mm is used.

Since the curing material is used for protection of the completed portion, no damage or dent is generated on the surface of the cured portion even if a local impact is applied from above the curing material such as dropping of a tool, and the curing material Even if foreign matter such as sand or canna dust enters between the surface of the completed part, the curing material is preferentially damaged to protect the surface of the completed part (prevention of sand bite).

Hard boards, MDFs, and plywood have high mechanical strength and surface hardness, so they have a high protection ability against local impact, but as described above, sawdust generated from the part under construction and adhered to workers. If foreign matter such as sand brought into the finished part enters between the surface of the finished part and a curing material such as a plywood (sand bite), the protected surface of the finished part will be damaged due to its mechanical strength and surface hardness. On the contrary, it was sometimes hurt.

Corrugated board has less mechanical strength and surface hardness than the surface to be protected, so even if sand bites occur, foreign matter can enter the bottom surface of the board (contact surface with the protected surface) and prevent damage to the protected surface. However, it is likely to be dented by a local impact, and when a tool or the like is dropped on the corrugated cardboard, it is dented as it is, and the surface of the relevant part of the completed part to be protected is also dented, and does not fully serve the role of protection.

Therefore, attention has been paid to the mechanical strength and surface hardness of fiberboards such as hardboards and MDFs, and an example in which this is used as a curing material has been proposed (Patent Document 1).
The invention of Patent Document 1 is a curing material formed by hot-pressing a wood fiber mat containing wood fibers as a main component and a synthetic resin binder added thereto, and a convex portion is formed on the upper surface of the curing material. .. This convex portion has a surface hardness of 1.5 kg/mm ² (Brunel hardness) or more. This curing material is a curing material having mechanical strength, high surface hardness, and excellent shape retention and workability.
However, if the convex portion of this curing material is laid on the protected surface with the convex portion facing downward, when the worker walks on the curing material, the hard convex portion is locally rubbed against the protected surface and the protected surface is protected. However, when the flat surface side was laid on the protected surface with the flat side facing down, sand entrapment could not be prevented as in the case of using a fiberboard such as a conventional hardboard or MDF as a curing material.

When an insulation board is used as a curing material for the above various curing materials, the insulation board is softer than a hard board or MDF, and therefore has excellent impact protection and sand bite prevention.

Utility model registration No. 3074251.

However, the thin insulation board has a lower fiber amount per unit area than the hard board and MDF. In particular, in the case of an insulation board manufactured by wet papermaking, the water content is large relative to the amount of fiber due to the characteristics of manufacture, so in the case of a thin (product thickness of less than 6 mm) wet roll, There is a problem that a wet mat hangs down between rolls during transportation and sneak under the rolls, or unevenness in drying is apt to occur in a drying process of moving inside a dryer, causing warping and clogging inside during drying. Therefore, a certain amount of thickness is required for manufacturing the insulation board, and experience has shown that the minimum product plate thickness is 6 mm.

Further, when the insulation board is used as a curing material, it is used in a large amount at a construction site. Therefore, when the board thickness is large, its bulk and its weight are large. Therefore, there is a claim that the transportation cost is high and a large storage space is required, and therefore, there has been a demand from the construction site to reduce the thickness and weight.

The present invention has been made in view of the problems of the conventional example described above, and in manufacturing a thin insulation board due to a demand for weight reduction, a thin insulation that can solve at once a request for problems during drying. It is an object of the present invention to provide a ration board and a manufacturing method thereof.

Claim 1 is a method for manufacturing a thin insulation board 1,
The wet mat 11 is formed by wet-fabricating wood fibers and adjusting the thickness so that the plate thickness after drying is 3 mm as the lower limit and 6 mm as the upper limit.
The water-based resin liquid 7 is applied and penetrated on one surface of the wet mat 11,
Then, the wet mat 11 is inserted into the dryer 30 with the coating surface 4 coated with the water-based resin liquid 7 facing upward,
The lower surface on which the water-based resin liquid 7 is not applied is placed on the roller 32 of the dryer 30 and conveyed, and is passed through the dryer 30 to dry the wet mat 11 and the water-based resin liquid 7 It is characterized by drying while aggregating.

As a result, since the water-based resin liquid 7 is dried while being agglomerated and dried in the dryer 30, the thin wet mat 11 can be prevented from warping or dripping. FIG. 4 schematically shows the rising portion 13 and the hanging portion 12.

A second aspect of the present invention is the method for manufacturing the thin insulation board 1 according to the first aspect, wherein the aqueous resin liquid 7 for forming the coating and aggregating layer 5 is any one of vinyl acetate type, acrylic type and urethane type. Is characterized in that These water-based resin liquids 7 aggregate in the coating aggregation layer 5 of the wet mat 11 during drying. Therefore, the characteristics of the thin insulation board 1 are not lost even in the coating aggregation layer 5.

A third aspect of the present invention is the method for manufacturing the thin insulation board 1 according to the second aspect, wherein the concentration of the water-based resin liquid 7 is 1 to 30% by weight.

By setting the concentration of the water-based resin liquid 7 to 1 to 30% by weight, it is possible to exhibit cohesiveness and at the same time maintain the soft characteristics of the dried coating and aggregating layer 5.

In the present invention, the wet mat 11 is sent to the dryer 30 with the coating surface 4 on which the water-based resin liquid 7 is applied and permeated upward, and the wet mat 11 is dried together with the water-based resin liquid 7. Due to the presence of 7, the abrupt drying from the upper surface of the wet mat 11 is suppressed at the time of drying, and the warp of the wet mat 11 during drying can be prevented even if the wet mat 11 is thinner than before. At the same time, due to the resin cohesive force of the aqueous resin solution 7 during drying, tension in the shrinking direction is generated on the upper surface side of the thin wet mat 11 and the sagging between the rollers 32 can be prevented. As a result, the thin insulation board 1 which is thinner than the conventional one and suitable as a curing material can be manufactured.

It is sectional drawing of the thin insulation board of this invention. It is a schematic diagram of a resin liquid application process and a drying process of the thin insulation board of the present invention. It is a schematic diagram of the application process of the formaldehyde adsorbent on the back surface of the thin insulation board of the present invention. It is a schematic diagram when a thin insulation board hangs between rollers of a dryer.

Hereinafter, the present invention will be described with reference to FIGS. 1 to 3. The present invention is a thin insulation board 1 suitable as a curing material. The thin insulation board 1 is manufactured by the above-mentioned known wet papermaking method, and has a product plate thickness of 3 to less than 6 mm, a fiber amount of 0.8 to ² kg/m ² , a width of 700 to 1,000 mm, and a length of 1. It is 400 to 2,000 mm.

In the thin insulation board 1, a thermoplastic water-based resin liquid 7 (or a resin liquid of a two-liquid water-based resin composed of a curing agent and a resin liquid) is applied to one surface of an insulation board body 2. , Part of which penetrates from the coating surface 4 to the inside in the vicinity of the surface. This portion is referred to as a coating aggregation layer 5.
In the dry state, the coating and aggregating layer 5 of the thermoplastic water-based resin liquid 7 is formed on the entire surface of the insulation board body 2. However, the coating and aggregating layer 5 only penetrates and aggregates the aqueous resin liquid 7, and does not form a hardened layer. Therefore, the coating aggregation layer 5 does not lose the flexibility peculiar to the insulation board.
If necessary, a water repellent such as petroleum wax is also applied to the application surface 4. The other surface of the insulation board body 2 is impregnated with a formaldehyde adsorbent. This impregnated layer is indicated by reference numeral 9. The thin insulation board 1 is suitable as a curing material, but of course, its use is not limited to the curing material, and may be used for other purposes.

The thin insulation board 1 is manufactured by the known wet papermaking method as described above. For example, wood chips obtained by steaming wood chips and defibrating with pulper are dispersed in a large amount of water to form a slurry by adding a binder (starch), a sizing agent and the like.

(Wet mat formation process)
In the wet mat forming step, the slurry is wet-processed by a gauze machine or the like to form a long continuous wet mat 11. The thickness and shape of the wet mat 11 can be adjusted with a dewatering roll such as a roll press if necessary.
The wet mat 11 containing a large amount of water is placed on the carrying rollers 33 installed at predetermined intervals and carried to the dryer 30. During the transportation from the wet papermaking machine, the product is pressed or rolled as described above so as to have a thickness of 3 to less than 6 mm, and adjusted to a predetermined thickness.

(Coating process)
After that, during transportation to the dryer 30, the water-based resin liquid 7 is sprayed from the spray nozzle 20 installed above the wet mat 11 and evenly applied to the upper surface of the wet mat 11. The applied water-based resin liquid 7 permeates as it is from the upper surface of the wet mat 11 to a certain depth. (The coating of the water-based resin liquid 7 may be performed by a roll coater (not shown) instead of the spray nozzle 20.)

Functionally, the applied liquid 7 is applied between the fibers within the coating surface 4 which is the upper surface of the wet mat 11 and its permeation range (coating aggregation layer 5) when it is dried together with the wet mat 11 in the dryer 30. Aggregates in the gap to reduce the gap to suppress rapid evaporation of water from the upper surface of the wet mat 11, and the tension in the contraction direction is generated by the cohesive force of the coating surface 4 of the wet mat 11 and the coating aggregation layer 5. Any material that can be generated may be used.
Examples of such a resin liquid include a thermoplastic water-based resin liquid, and examples thereof include vinyl acetate-based, acrylic-based, or urethane-based water-based resin liquids. As another example, a resin liquid, which is one liquid of a two-liquid aqueous resin liquid composed of a curing agent and a resin liquid, is used.
The concentration of the aqueous resin liquid 7 used is 1 to 30% by weight. When the concentration is less than 1% by weight, the cohesive force during drying is weak and the warpage and sagging cannot be eliminated. When the concentration exceeds 30% by weight, the viscosity becomes high and spraying becomes difficult.

When an appropriate amount of the water-based resin liquid 7 is evenly applied to the upper surface of the wet mat 11 as described above, a part of the water-based resin liquid 7 penetrates from the upper surface (application surface 4) of the wet mat 11 to the inside at a slight depth.
When the coating process of the water-based resin liquid 7 is completed, it is sent to the dryer 30 as it is by roller conveyance.

(Drying process)
Hot air is supplied into the dryer 30 and is maintained at 150 to 200°C. In the dryer 30, a transfer conveyor 34 and rollers 32 are installed in multiple stages at predetermined intervals so as to be continuous with the roller conveyance in the coating process, and the wet mats 11 sent into the dryer 30 have different stages. Rolling is slowly carried out, and drying is performed in the meantime. In this drying step, the wet aqueous resin liquid 7 impregnated from the coating surface 4 of the wet mat 11 into the coating and aggregating layer 5 in the vicinity thereof gradually loses water and aggregates as described above. The coating aggregation layer 5 on the upper surface side of the wet mat 11 fills the gaps between the fibers of the wet mat 11 to some extent, and hinders rapid evaporation of water from the coating surface 4 that is the upper surface of the wet mat 11. At the same time, the cohesive force causes the coating and aggregating layer 5 of the aqueous resin liquid 7 to generate a tension in the shrinking direction on the upper surface side of the wet mat 11.

The inhibition of the rapid evaporation of water from the coating surface 4 of the wet mat 11 of the coating and aggregating layer 5 of the water-based resin liquid 7 prevents the wet mat 11 from warping upward. The tension in the shrinking direction of the coating and aggregating layer 5 on the upper surface side of the wet mat 11 causes the lower surface side of the wet mat 11 containing a large amount of water to hang down between the rollers 32 on the upper surface side of the wet mat 11. Since the wet mat 11 is pulled without being stretched, the wet mat 11 is prevented from dripping between the rollers 32. In particular, in the thin wet mat 11 which is a material of the thin insulation board 1 having a size of less than 6 mm, contains a large amount of water, is easily warped, and is liable to sag, the presence of the coating aggregation layer 5 facilitates the drying process smoothly. It is essential. The presence of the coating aggregation layer 5 contributes to the improvement of the durability of the thin insulation board 1.

(Cutting process)
The wet mat 11 that has exited the dryer 30 is sufficiently dried and becomes a long raw material of the thin insulation board 1 having the coating and aggregating layer 5 of the aqueous resin liquid 7 formed on the coating surface 4. This long original fabric is cut into a predetermined width and length to form a thin insulation board 1 having a thickness of 3 to less than 6 mm.
When this thin insulation board 1 is used as a curing material, a form coater 40 is coated with a formaldehyde adsorbent on the surface opposite to the coating surface 4 as shown in FIG.

The formaldehyde adsorbent to be applied to the back surface of the thin insulation board 1 is selected from those which are harmless and stable, easily react with formaldehyde, and the product does not dissociate formaldehyde. Specifically, imidazolidones are imidazolidinone, imides are diacetylimide, phthalimide, amines are melamine, naphthylamine, cyclohexylamine, diamylamine, and amides are urea, ethyleneurea, propyleneurea, and 5-hydroxy. Examples thereof include propylene urea, 5-methoxyfuropylene urea, 5-methylpropylene urea, parabanic acid (glyoxalmonourein), 4,5-dimethoxyethyleneurea, pyrrolidine, piperidine, morpholine, dicyandiamide or a derivative thereof.

In the roll coater 40, as shown in FIG. 3, the coating roll 42 is rotatably arranged in a tank 44 containing an aqueous solution 46 of formaldehyde adsorbent, and the coating roll 42 projects upward from the liquid surface of the aqueous solution 46. The thin insulation board 1 having a constant width and length on the top of the upper surface of the coating roll 42 is conveyed in one direction by the roller 32 so that the back surface thereof is in contact, and formaldehyde adhering to the surface of the coating roll 42. The aqueous solution 46 of the adsorbent is applied to the back surface of the thin insulation board 1. The aqueous solution 46 of the formaldehyde adsorbent applied to the back surface of the thin insulation board 1 permeates from the back surface to the inside through the innumerable small gaps formed between the fibers of the thin insulation board 1 and a part of the thin insulation board 1. By adhering to the back surface of the insulation board 1 and drying in this state, the impregnated layer 9 of the formaldehyde adsorbent that is firmly fixed to the thin insulation board 1 and is difficult to peel off is formed.

The application of the formaldehyde adsorbent may be performed by spraying instead of the roll coater 40, or the water-based resin may be used during the transportation of the wet mat 11 by the transportation rollers 33 instead of the dried thin insulation board 1. The coating with the coating roll 42 may be performed before or after the spray coating of the liquid 7.

The thin insulation board 1 used as a curing plate is a back surface on which a formaldehyde adsorbent impregnated layer 9 is provided during the construction of a house after the construction of the wooden floor material and before other interior work is completed. Is laid in contact with the finished wooden flooring.
As a result, when the operator accidentally drops the tool, the soft upper surface (coating surface 4) of the thin insulation board 1 laid as a curing plate absorbs the impact at the locally hitting point at the drop point, and This will prevent the wood flooring, which is the protective surface, from being dented or scratched. In addition, even when foreign matter brought in from the outside when the worker walks on the thin insulation board 1 such as sand, plane scraps, and other foreign matter enters between the thin insulation board 1 and the completed wooden floor material, The foreign matter does not preferentially enter the back surface of the thin insulation board 1 with respect to the completed wooden floor material that is the protected surface, and does not damage the wooden floor material.
In addition, by providing the coating and aggregating layer 5 of the water-based resin liquid 7 on the coating surface 4 of the thin insulation board 1 of the present invention, the hardness of the portion does not increase as described above and the softness is maintained, but the durability is improved. Even if it walks frequently on the thin insulation board 1 laid as a curing plate, it will not be worn out.

In addition, formaldehyde which is volatilized from the wooden floor material is chemically adsorbed by the formaldehyde adsorbent (and physically adsorbed by the sparse fiber structure of the thin insulation board 1) to trap it, thereby preventing deterioration of the indoor environment.
Next, specific examples in which the present invention is used as a curing plate will be shown together with comparative examples.

養生材の材質は以下の通りである。
なし：養生材で被保護面を保護しない場合
ＨＢ：ハードボード 合板：2.5ｍｍ広葉樹合板 ＭＤＦ：中密度繊維板
段ボール：紙製 プラダン：プラスチック段ボール
６ｍｍ厚のインシュレーションボード 本発明品:３〜６ｍｍ未満厚の薄物インシュレーションボード

×・○は目視判定
×：凹み、砂噛み発生 ○：砂噛み、５０ｃｍの落球試験で凹み発生せず The following is a performance comparison table (falling ball test, sand bite test) when various members are used as a curing material. Pass/fail judgment is based on the presence or absence of scratches or dents visually. In the application as a curing material, in the drop ball test, pass/fail judgment was performed by the presence or absence of scratches or dents from a height of 50 cm.
Falling ball test: Iron ball weighing 500 grams Height of falling ball: 50, 70, 100 cm
Sand bite test: test sand

The material of the curing material is as follows.
None: When the surface to be protected is not protected by a curing material HB: Hardboard Plywood: 2.5 mm Hardwood plywood MDF: Medium density fiberboard Corrugated board: Paper Pradan: Plastic corrugated board 6 mm thick Insulation board Product of the present invention: 3 to less than 6 mm Thick thin insulation board

×・○ is visually judged ×: Dent, sand biting occurred ○: Sand biting, no dent occurred in the 50 cm drop ball test

In Tables 1 to 3, except for the thickness of 6 mm and the insulation board of the present invention, the 50 cm falling ball test and the sand bite test failed, but the insulation board passed all the tests.
However, since the insulation board having a thickness of 6 mm has a large plate thickness of 6 mm, it is bulky and heavy. On the other hand, the thin insulation board of the present invention is inferior to the insulation board having a thickness of 6 mm in the falling ball test of Table 1, but does not cause dents in the falling ball test of 50 cm, and from the viewpoint of weight reduction. It can be said that it is practical as a curing material.

1: Thin insulation board, 2: Insulation board main body, 4: Coating surface, 5: Coating aggregation layer, 7: Water-based resin liquid, 9: Impregnation layer, 11: Wet mat, 12: Hanging part, 13: Warpage Part: 20: Spray nozzle, 30: Dryer, 32: Roller, 33: Conveying roller, 34: Transfer conveyor, 40: Roll coater, 42: Coating roll, 44: Tank, 46: Aqueous solution

Claims (3)

Wet papermaking of wood fibers is performed, and the thickness is adjusted so that the plate thickness after drying becomes a lower limit of 3 mm and an upper limit of 6 mm to form a wet mat.
A water-based resin liquid is applied and penetrated on one surface of the wet mat,
Then, insert the wet mat into a dryer with the coating surface coated with the water-based resin liquid facing upward,
The lower surface on which the water-based resin liquid is not applied is placed on a roller of a dryer and conveyed, and passed through the dryer to dry the wet mat while aggregating the water-based resin liquid. And a method for manufacturing a thin insulation board. The method for producing a thin insulation board according to claim 1, wherein the aqueous resin solution for forming the coating and aggregating layer is any one of vinyl acetate type, acrylic type, and urethane type. The method for manufacturing a thin insulation board according to claim 2, wherein the concentration of the aqueous resin liquid is 1 to 30% by weight.

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