JPH0149086B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing mineral fiberboard having excellent fireproofing, heat insulating and sound absorbing properties and used as ceiling panels and other building materials.

(Prior art and its problems) Traditionally, as a method for manufacturing mineral fiberboard,
Generally, a continuous wet papermaking method or a paste method is known.

The former continuous wet papermaking method has the advantage of producing mineral fiberboard with high bending strength;
The surface has the disadvantage that it has no pattern and is poor in cosmetic properties.Therefore, a moth-eaten pattern is formed on the surface by embossing, etc., but since it is applied mechanically, the pattern is unnatural. In order to create a more natural pattern, it is necessary to combine various processes.

On the other hand, according to the latter paste method, a large number of natural-looking pores are obtained on the surface of the fiberboard, and it has excellent cosmetic properties, but the mineral fiberboard obtained by this method has a low bending strength. There is a problem that the size is small and continuous production is not possible.

Therefore, if a pattern is formed by a paste layer on a fiber substrate obtained by the former continuous wet papermaking method, a mineral fiberboard with high mechanical strength and good design should be obtained. Since the viscosity of the paste used in the paste method is extremely high, it is difficult to form the paste layer integrally on the surface of the fiber substrate, and it has to be manufactured separately and then integrated. There were problems such as requiring time and effort and not being able to carry out continuous production.

(Purpose of the Invention) The present invention was made in view of the above problems, and it is a mineral that has excellent mechanical strength and has a pattern formed by a paste layer mainly composed of mineral fibers on the surface layer. The present invention provides a method for continuously producing quality fiberboard.

(Structure of the Invention) In order to achieve the above object, the method for producing a mineral fiberboard according to the present invention is to produce a mineral fiberboard containing mainly mineral fibers on a wet mineral fiber mat obtained by continuous wet papermaking. After providing a paste layer and forming a concave pattern with irregularly shaped openings on the entire surface of the paste layer, air is blown onto the surface of the mineral fiber mat having the patterned paste layer, and suction is applied from the back side for dehydration. It is characterized by reducing the moisture content by heating and drying it, and it mainly consists of mineral fiberboard obtained by wet papermaking method and mineral fiber obtained by paste method. The structure is such that the fiber layer and the fiber layer are simultaneously and reliably integrated.

(Explanation of Examples) An example of the present invention will be described with reference to the drawings. Mineral fibers such as rock wool and slag wool are mixed with appropriate aggregates and waste paper pulp as necessary, and a binder such as starch is added. The slurry obtained by adding an appropriate amount is subjected to continuous wet paper-making in a conventional manner using a known means such as a round net or Fourdrinier machine to obtain a wet mineral fiber mat 1.

On the other hand, mineral fiber is the main ingredient, and appropriate binders and thickeners are mixed with this, and the solid content of this mixture is 100%.
After adding 180 to 250 parts of fresh water to the mixture, knead to obtain a paste. This mineral fiber paste has a higher water content and is adjusted to have a lower viscosity than pastes used in conventional paste methods. This is because if the amount of water contained in the paste is small, the adhesion with the mineral fiber mat 1 will be reduced and it will be difficult to layer them together, and if the water content is too high, the paste layer will be This is because it becomes easy to collapse, making it difficult to form a concave pattern.

The mineral fiber paste whose water content has been adjusted in this way is applied to the surface of the wet mineral fiber mat 1 while the mat 1 is being transported to form a paste layer 2 of an appropriate thickness.

Next, a large number of moth-eaten concave patterns 3 having irregularly shaped openings 4 are formed on the surface layer of this paste layer 2.

This concave pattern 3 may be formed by a roll having a blade-shaped pattern, or as shown in FIG.
The paste layer may be formed by rubbing the surface of the paste layer with a roll 5 rotating at a circumferential speed different from the conveyance speed.

In this case, when the roll 5 rotating at a circumferential speed different from the transport speed of the mineral fiber mat 1 rubs the surface layer of the paste layer 2, the surface layer of the paste that is rubbed and the lower layer of the paste that is not rubbed are separated. Due to the different movement speeds, the surface layer is torn off from weak points at many points on the surface, forming a zigzag pattern 3 with openings 4 diagonally upward.If the surface is ground flat after drying, it will look like a moth-eaten pattern. A concave pattern 3 can be obtained.

The mineral fiber mat 1 with the paste layer 2 patterned in this way is transported by blowing air 6 onto the surface of the paste layer 2 from above and by using a vacuum suction device (not shown) from the back side of the mineral fiber mat 1. 7) aspirate and dehydrate.

By blowing this air flow and suctioning from the back side, the moisture content of the mineral fiber mat 1 is reduced by about half, and if it is press-dehydrated using a known roll or the like, the opening pattern 3 on the surface will not be deformed. However, according to such a dehydration method, a predetermined concave pattern 3 can be maintained.

Furthermore, since the concave pattern 3 has openings 4 in the paste layer 2, airflow passes through the mineral fiber mat 1 and dewatering is easily performed, and the mat 1 is easily dehydrated by dehydration.
The weight of the mat 1 is reduced, and the waving of the mat 1 due to conveyance rolls (not shown) or the like is eliminated, and subsequent drying using a dryer can be performed quickly.

Note that even if such dehydration using air flow is employed in the conventional paste method, the concave pattern openings penetrate between the front and back surfaces, and a sufficient drying effect cannot be achieved.

The mineral fiberboard thus obtained is ground to a flat surface, if necessary, in order to remove raised portions around the pattern.

As described above, according to the method for manufacturing a mineral fiberboard according to the present invention, since the mineral fiber mat serving as the substrate is obtained by a continuous wet papermaking method, a fiberboard with high bending strength can be obtained. Of course, since a paste layer mainly composed of mineral fibers is provided on the mineral fiber mat in a wet state, it is possible to easily form a concave pattern with irregularly shaped openings on the surface of the paste layer. After forming the concave pattern, air is blown onto the surface of the mineral fiber mat having the patterned paste layer and suctioned and dehydrated from the back side, so that the concave pattern formed in the paste layer is not deformed. Air flows through the mineral fiber pine through the openings in the concave pattern, greatly reducing the moisture content. Therefore, it can be dried in a short period of time, and can be formed into a mineral fiberboard having the desired strength and surface finish, and excellent fireproofing, heat insulating, and sound absorbing properties.

Further, according to the present invention, since the paste layer is provided on the wet mat, warping hardly occurs, and the drying process described above is performed at once, and the drying process is also performed in a short time, which saves energy. Further, it is possible to continuously produce a mineral fiberboard having a concave pattern such as a moth-eaten pattern on the surface.

[Brief explanation of drawings]

The drawings show an embodiment of the present invention, and FIG. 1 is a side view thereof, and FIG. 2 is a sectional view showing a state in which a pattern is formed. 1...Mineral fiber matte, 2...Paste layer,
3... Concave pattern, 4... Opening.

Claims (1)

[Claims] 1. A paste layer mainly composed of mineral fibers was provided on a wet mineral fiber mat obtained by continuous wet papermaking, and a concave pattern with irregularly shaped openings was formed on the entire surface of the paste layer. Afterwards, air is blown onto the surface of the mineral fiber mat having the patterned paste layer, and air is sucked from the back side to dehydrate it to reduce the moisture content, and then heated and dried. Production method.