JPH01501859A - Low density mineral wool panel and its manufacturing method - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] Low-density mineral wool panel and its manufacturing method Technical field The present invention relates to a method for producing mineral wool fiber products, particularly those having a density of about 3 per cubic foot. Extremely lightweight mineral wool fiber of ~10 bond (50-160 kg/m”) Soundproofing and resistance to sound absorption ceiling tiles, insulation panels, sound absorption panels, beam sound, etc. This paper relates to a method for manufacturing strong panels for structural materials such as buildings used as thermal products.

Background technology Construction using water felt of a dilute aqueous dispersion of mineral wool and light aggregates The formation is well known. The dispersion liquid is poured into a moving support wire belt with a porous structure and gravity is used to The resulting wet mat is still Since it contains 60 to 80% moisture, it is dried in a convection oven for a long time, and The mats thus created are cut, surface treated with paint, etc. as necessary, and sound-absorbing ceilings are installed. Create panels for lightweight structural materials such as well products.

It is also known to make foams stabilized in part by mineral wool. example For example, U.S. Pat. No. 4,447,560 includes synthetic rubber roughtex solids. A method is proposed to create a first fiber slurry and create a low density insulation sheet. Ru. In this case, further detergent slurries are made and these slurries are reduced to a coarseness of 15% solids. Mix and stir to form a stable foam, then dry in an oven. Ru. However, this method requires significantly more time to create the product, with 15% It takes a lot of energy to dry and form a stable foam from solids. , which is unfavorable from an economic point of view.

U.S. Pat. No. 3,228,825 also states that Approximately 1 to 3 bonds per cubic foot (16 to 50 kg) using lightweight foam materials We manufacture extremely lightweight pipe wrap with a density of /m3). A method has been proposed to create This foam can be used, for example, in panels for hanging ceiling grids. Even if it is supported only at the edges, it has sagged, bent, or broken to a visible degree due to its own weight. It is unsuitable for "structural materials" that require no damage. The U.S. patent The fibers are made of highly purified cellulose fibrids that create fine bubbles. Foam is created by evenly mixing lightweight aggregates and attenuated glass fibers using fiber adhesive. Obtain the encapsulating mixture.

Additionally, very small amounts of aggregates such as polyacrylamide can be added to form mineral fibers. It is known to aggregate inorganic clays in dilute dispersions. U.S. Patent No. 3.510 ．． As disclosed in No. 394, this aggregate forms clumps between the fibers and increases the weight of the mat. Contained in the dehydrated liquid released during dehydration by force, starch and clay are significantly lost. It must be added just before the slurry is dehydrated to prevent it from being washed away.

Further, U.S. Pat. No. 4,062,721 discloses that the mat is placed on a wire belt and We minimize foaming during the initial gravity dehydration process, and then we try to minimize foaming in the following steps. A configuration is disclosed that allows foaming and avoids foaming within the forming box.

The object of the present invention is to have a density of about 3 to 10 bonds per cubic foot (50 to 160 kg/+a”) with a modulus of rupture of approximately 60 bonds per square inch. Our goal is to provide mineral panels.

According to the invention, a delicately effervescent binder and a slightly ionically bonded cationic Mixer of guar gum with a substantially non-foaming non-ionic surfactant dispersant After that, it is deposited on the wire belt section and intertwined with the fibers, creating a porous structure. Obtain a structure that allows air to pass through, and then dehydrate and dry it to create an extremely strong and low density structure. Obtain mineral wool panels. According to this production method, the dehydration time is longer than that of the conventional method. For example, even if the panels are supported only at the edge of a suspended ceiling grid, Extremely dense structures that can be supported without heavy, visible sagging, curvature, or failure. It is possible to produce panels with low degrees of strength.

ethyl fist alcohol The ionic polyethanoxy surfactant contains approximately 6% protein with some residual acid content. Wheat starch binder with distillate protiin and trimethylammoniopropylene Small amounts of cationic guar gum or guar bis, such as Le Gua Chloride Polymer When added to a composition containing a corn meal derivative, the composition initially erupts slightly. At the same time, the ingredients are effectively ionically bonded to each other and the mineral wool is dispersed. Mineral wool is intertwined to obtain a wet mat with pores, and then quickly removed from the wet mat. It can be dehydrated quickly and allows a large amount of heated dry air to pass through at a fast speed. Can perform dehydration.

Brief description of the drawing The drawing is a simplified illustration of the mineral board manufacturing method according to the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION Approximately 3% to An aqueous slurry 14 containing about 6% solids is mixed. Solid content of this aqueous slurry 14 consists of the following components:

Ingredient amount Mineral wool approximately 25 ru 95 Wheat starch approximately 10-30% Cationic guar derivative: approx. 0.03~1% Nonionic surfactant: approx. 0.5~3% Clay maximum about 5% Commercially available wheat starch containing approximately 6% protein (e.g. Ogilibi Mills) ・Sold by Inc. (Ogjlyie former IIs, Inc.) ) is a high shear cyclone mixer] 8 as well as a part of the processing inside the mixing tank 16. Dispersed in water and heated to a temperature of approximately 1350F to 190F (57C to 88C). Boil the starch. The viscosity of the starch does not increase significantly during this boiling, After boiling, feed the starch binder to mixing tank〕0. At this time, the important point is To maintain high dewatering and drying rates of the mat, harmful binders may be used. This means that the viscosity of the slurry does not increase significantly.

Good dispersion of mineral wool and aggregates in diluted slurry to form a porous mat Add a non-ionic polyethane surfactant to the slurry in the mixing tank Ru. This non-ionic polyethanoxy surfactant is manufactured by G.A.F. Chemicals. ・GAF Chemicals Corporation It is preferred to use an approximately 2% solution, which is sold separately. mineral wool and Light aggregates are combined with wheat starch binder protein and minerals via cationic guar. To ensure complete dispersion on the surface, add cationic guar gum derivative aggregates and Eat starch binder protein binds ions to mineral surfaces via cationic guar. Further, the slurry is passed through the head box 3o and settled on the wire belt section 40. Let it foam to a low level before laminating.

Mineral fibers used in the present invention include molten basalt, slag, granite, etc. It is obtained by drawing out the glassy mineral component in a line from the orifice and making it delicate. The so-called textile fibers, or the above-mentioned molten mineral components, are tangential to the surface of the spinning rotor. So-called wool fibers obtained by drawing in the direction of For example, aromatic polyamide fibers can be used. Also, panels can be created according to the present invention. The porous bonded mat fibers can be used as individual fibers in the process.

It is preferable to use exfoliated or foamed glassy volcanic rock as the lightweight aggregate. stomach. As for this aggregate, as is well known, foamed material that can be obtained in various mesh sizes is used. Examples include pearlite, exfoliated vermiculite, exfoliated clay, and the like. Generally available and economical From this point of view, it is preferable to use expanded pearlite.

The homogeneously mixed, ionically bonded and slightly foamed slurry is transferred to the wire belt section 40. The mineral wool and lightweight aggregates are intertwined and formed into a constant small temporary It is possible to obtain a composition having a porous structure in which a small amount of pores are present. At this point The proportion of pores in the composition is approximately 10-30% by volume, with the remaining light weight The void between the aggregates and the preferred nonionic polyethanoxy surfactant has a molecular weight of There are approximately 995 dinonylphenolic agents. Commercially available ethyl acetate with similar properties Alcohol polyester ether can also be used.

Guar 2-hydroxy 3(trimethyl-amino)-propyl ether chloride trimethylammoniopropyl gua (Henkel Corporation) Trade name GEND[) sold by (Henkel Corporation) Add the cationic bean meal derivative of polymer powder to the mixing tank 10 and add it to the water. Mineral wool and expanded perlite dispersed and added directly to the mixing tank 10 It has a suitable concentration that exhibits cohesive or solids retention properties with lightweight aggregates such as A solution is obtained. Guar derivatives give mineral wool a tendency to agglomerate. child The flocculating effect of is enhanced by the addition of small amounts of clay.

After thoroughly and homogeneously mixing all other ingredients, the cationic guar derivative is finally added. Add to the mixing tank 10, mix for a few seconds, then pump 20 to the mixing tank】0 to Send to head box 30.

The head box 300 function is to create a homogeneous slurry across the width of the wire belt section 40. The purpose is to spread it so as to form a layer 32 to form a wet maturo 2 having a porous structure. wet The thickness of Matsutoro 2 is the preferred thickness to obtain a final product with a thickness of approximately 174 to 2 inches. be made into

What is important in the production method of the present invention is that the nonionic polyethanoxy surfactant is Its foamability is low (for example, cations are added to the mixing tank 10 during the initial mixing operation). Mineral wool and lightweight aggregates are added along with guar gum derivative aggregates. Ionic bonding of wheat starch binder protein via cationic guar on the surface of the membrane. After completely dispersing the mixture and passing the slurry through the head box 3°, the wire belt section 4 The aim is to provide low foaming properties on top of zero and spread it.

The mineral fibers used in the present invention include those mentioned above (molten basalt, slag , obtained by drawing out glassy mineral components such as granite in a line from an orifice and making them delicate. The so-called textile fibers that are produced, or the molten mineral components mentioned above, are transferred to the surface of the spinning rotor. So-called wool fibers, which are obtained by drawing tangentially from Polyamide fiber or aromatic polyamide fiber can be used. In addition, according to the present invention, the panel The porous bonded mat fibers can be used as individual fibers in making the fibers.

As a lightweight aggregate, this is also exfoliated or foamed glassy volcanic rock as mentioned above. It is preferable to use this aggregate, and as is well known, various types of mesh Examples include expanded pearlite, exfoliated vermiculite, and exfoliated clay.

Generally, it is preferable to use expanded pearlite from the viewpoint of availability and economy.

However, as mentioned above, the slurry is homogeneously mixed, ionically bonded, and slightly foamed. The mineral wool and lightweight aggregates are intertwined with each other. A composition with a porous structure in which a small amount of small temporary pores are present can be obtained. this At this point, the proportion of pores in the composition is about 10 to 30% by volume of the composition, and the remaining Water-containing voids are formed between the lightweight aggregate and the mineral fibers, and this aqueous slurry Li is about 3-6% solid double star at this point. Foaming wet composition head box 30 to the bottom scrim cover sheet 43 on the wire belt section 40 at the sink section 42. deposit.

Dewatering from the slightly foamed composition is accomplished by adding a scrim top cover sheet 47. In addition, as the composition is placed on the composition via the roller 36, it is carried out in the high pressure reduction section 44.

In the high decompression section 44, a short pipe corresponding to approximately 3 to 20 inches (0.8 to 0.5 m) is used. The russian pressure destroys the pores within the composition and causes dehydration. At this stage, The pores are destroyed for about 1-3 seconds and the fibers and aggregates are entangled with the dehydrated liquid at the bottom of the scrim. It was observed that it was applied at the contact points with the cover sheet.

Continuously decompressing the mat in the high decompression section 46 and the high decompression section 48 simultaneously By passing a large amount of heated dry air at high speed, the pores are not destroyed. Continuously dehydrate and dry the mat. Non-woven fiberglass scrim cover on both sides structural mineral panels with a density of about 3 per cubic foot. ~10 Bond (50-160 kg/m”), preferably about 3 to 6 bonds (50 to 1 (lokg/m')) with a rupture coefficient of approximately 60-120 bond (42,000-84,000kg/m3), wire bell Composition comprising about 3-6% by weight of the head box 30 on the head section 40 The time required to obtain the product in the dryer 49, which dehydrates and dries it by passing air, is It takes about 10 minutes or less. At this time, after the panel passes through the high pressure reduction section 48, the moisture content is approximately 3 %. Thermal panels are increased through air using a well-known convection dryer (not shown). By increasing the drying time by about a few minutes, more sufficient drying can be achieved.

In the configurations described above, the mat is covered with one or two non-woven fiberglass scrim cover sheets. It is integrally formed with the seat. This cover sheet can be paper, woven glass fiber, non-woven glass A porous sheet material such as fiber can be used. Particularly preferable cup<-sheet A non-woven fibrous scrim having a weight of approximately 0.4 to 2.5 bonds per hundred square inches. can be mentioned. As a one-sided embodiment, the scrim top cover sheet 47 is removed. After dehydration and drying in the dryer 49, for example, US Pat. No. 1.769.51 No. 9, No. 1.996.033 and No. 3.246.063. Apply the viscous bulb onto the mat and apply it to a suitable device such as plasterboard. The entire surface is dried using a well-known convection dryer (not shown) which imparts a more desirable appearance to the surface. may be dried. Furthermore, the panel obtained according to the present invention has both top and bottom screen. A damping sheet can also be applied before applying the valve. Further undercoat and pattern addition It is also possible to perform various finishing operations such as protective coating.

Experimental examples of the present invention are listed below. Amounts are based on total dry solids unless otherwise specified. is expressed as a percentage of Thermal theory The present invention is not limited to these experimental examples. will be understood.

Experimental example 1 Cationic bean meal derivative (guar 2-hydroxy 3 (trimethylammo) (Nio)-propyl ether chloride; Henkel Corporation (Hen Trade name GENDRIVE 1 sold by KEL Corporation 58) was put into the auxiliary mixing tank 16 shown in the drawing together with water to prepare an aqueous solution. Mi neral wool, foamed perlite aggregate, dinonylphenoxy poly(ethylene chloride) Available from GAF Che+wicals Corporation Trade name IGEPAL-DM710), nonionic polyethanoxy surfactant and CTS ball clay was placed in mixing tank 10 and mixed for 4 seconds.

This cationic guar derivative liquid is added to the mixing tank ] 0 and coagulated into the head box 3. Mixed for 5 seconds before passing to zero. Regarding the solid content, in the final formulation in mixing tank 10, , mineral wool 44.5%, expanded perlite 29.15%, wheat flour Turch is 2L 95% (6% residual protein content, Ogilvie Pulse Parakeet) sold by Ogilvie Mills Inc. Trade name: GENVIS 600T 190°F (88°F) in auxiliary mixing tank 16 ℃), CTS-2 clay is 1.68% and about 3% isomorphic dispersion There is 1.68% nonionic polyethane surfactant in the liquid. This formulation is A head is dehydrated by gravity from the mixing tank 10 at the first stage of the wire belt section 40. Scrim (2.4 bond (0.1 2 kg/m") on a battery type non-woven glass fiber). The mat is extremely homogeneously intertwined with mineral wool and lightweight aggregates, and contains small non-woven materials. It was found that the structure had elastic pores. Water in the high pressure reduction section 44 A vacuum corresponding to approximately 15 inches (0.4 m) is applied to the silver column in a very short period of time (1 second). water is added in a liquid manner, immediately destroying the pores within the mat and drawing large amounts of water out of the mat. When removed, the bottom cover sheet 43, scrim top cover sheet 47 and fibers are removed. - The moisture content of the wet composition consisting of the porous structure core 41 of aggregate/clay is still approximately It was 75% by weight. After simple dehydration of the porous structure composition, the high vacuum section 46 ( drying of large quantities heated to a vacuum corresponding to approximately 5 inches of mercury (Olm) Air is quickly passed through the composition to dry it, and then the high vacuum section 48 (on the surface of the composition) (applying pressure corresponding to approximately 14 inches (0.4 m)) and dryer 49 (assembly). The surface area of the composition is approximately 300 cubic feet per square inch (0.09 m”). (8,5+a”) generally about 50 to 350 cubic feet (1,4 m’ to 10 m ’) (with air passing through D). In general, the temperature of the heated dry air is The temperature is 37-205°C, preferably about 175°C. Empty through head box 30 The passage time through the high vacuum section 48 that performs air drying is approximately 1/8 inch (0,003 m). varied according to core thickness of ~2 inches (0.05 m), but generally approx. I made it last for 10 minutes.

This produced several samples with various thickness, density and strength properties. . In this case, the average thickness of the core is 0.445 to 0.490 inches and the average density is cubic It came out to be 6.3 to 7.0 bonds per foot. (with the sample panel side down) The average modulus of rupture was 120 bonds per square inch and the acoustic properties were tested. The average noise reduction rate was 0.75.

Experimental example 2 Panel samples were prepared by halving or doubling the amount of some of the ingredients used in Experimental Example 1. We created it and conducted a series of evaluation tests. Some of the samples were dried by passing air. Measure the weight of the drained sample and then place the sample in a convection furnace. After drying overnight, it was made into a constant type fi (referred to as T-A-D treatment) and compared to the absolute dry weight. compared. The table below shows the results.

As is clear from the table, doubling the amount of lightweight aggregate will allow it to pass through and dry by air. The moisture content of the panel is increased. The viscosity of this sample increased considerably during preparation.

Also, doubling the amount of wheat starch with residual protein content will also increase the moisture content. increased in width. This sample also had a significant increase in viscosity during preparation. small amount of residual pro Wheat starch with tin can be used as a starch binder even when boiled. The viscosity of the binder does not increase and by using this preferred amount of binder the composition The viscosity remains low and the porous structure can be significantly dehydrated and dried by passing dry air through the composition. Shiuroko will be understood. Low foaming dispersant - surfactant nonionic polyester Of tanoxylate! Even if it is doubled, the properties of the inelastic pores do not change much, and the Even when air is passed through, the pores are not significantly destroyed and dehydrated. Fibers and aggregates were not significantly separated. Many traditional methods use perlite. formed by the separation or floating of starch or wool fibers, or by the separation or settling of starch or wool fibers. The water content became quite scrapy, and it was not possible to speed up the dehydration process. The important point of the invention is that the remaining Using a binder that does not increase viscosity by combining starches with distillate proteins , non-ionic foam that retains moisture to prevent dehydration through passing air, and slightly erupts. Polyethanoxylate dispersants - bonded with cationic guar gum using surfactants The wool and aggregates are dispersed, even when the wool and aggregates are entangled. Dispersion prevents ingredients from layering even during dehydration by passing air. There is a particular thing.

From the above description, it can be seen that according to the present invention, the present invention can be used for structural materials having a wide range of densities, properties and uses. It will be clear that a method of manufacturing a mineral panel product is provided. For example, the panel The thickness of the wall can be approximately 178 inches to 2 inches (0,003 to 0.05 m) or more. . and the dilute mineral fiber composition has a density of about 3 to about 10 pounds per cubic foot. An extremely lightweight product of 50 to 160 kg/m' can be obtained.

Other conventionally used ingredients and other adjuvants can also be used depending on the application. . For example, dyes, pigments, antioxidants, water repellents, flame retardants, biocides, etc. should be added as appropriate. Ru. Furthermore, the panels of the present invention are free from the cutting and triangulation methods employed in conventional panel manufacturing methods. work such as finishing, forming slots and tabs for hanging from ceiling grids, etc. It is also possible to perform surface treatments for finishing and decoration, as well as protective coating work, which can be done using the present invention. This is a matter that falls within the scope of technical thought. With conventional continuous patch panel forming equipment Mixers or sinks of various configurations, including turbines or impellers, used A head box can also be used.

West Ingredients Density Thickness Weight fi ff F (kg) After drying Humidity % lb/cubic ft Feet inch (1m) D-A-D F-Heavy electric weight difference (Kg/■3) Contains perlite! Sample 1 L 9.20 0.28 0.28 0.22 0.07 3 1.6 (147) (0,0071) (0,13) (0,10) (0,3 [+) Sample 2 14.6% 7.53 0.37 0.26 0.23 0.02 9.90 (121) (0,0094) (0,12) (0,10 ) (0,009) Sample 3 29.2% 6,64 0.46 0.30 0,25 0.85 20.20 (+06) (0,012) (0,14) (0,11) (0,02) Sample 4 58.3% 5.40 0.62 D, 42 0.28 0.14 48.60 (86,5) (0,016) (0,19) (0,13) (0,06) Starch content Sample 5 11.5% 6,76 0.49 0,32 0,28 0.0 4 +5.10 (10g) (0,012) (0,15) (0,13) ( 0.02) Sample 6 23.0% 5J9 0.44 0.27 0.22 0.06 25.6 (94,3) (0,011) (0,12) (0,1 0) (0,0:’l) Sample 7 45.9% 5.65 0,42 0, 46 0.20 0.26 132.30 (94,4) (0,011) (0 ,21) (0,09) (0,12) Guar content Sample 8 L 5.83 0.51 0.38 0.25 0.13 5 :1.40 (93,4) (0,013) (0,17) (0,11) (0 ,06) Sample 9 0.04% 5.7B 0.52 0.32 0.25 0.0? 29.00 (92,6) (0,0]3) (0,15) (0, 11) (0,03) Sample 100.08% 6.33 0.49 0.3 3 0.26 0.0g 29.40 (101,4) (0,012) (0, 15) (0,12) (0,04) sample 110.16% 6.61 0 ,46 0,32 0.25 0.07 28.00 (105,9) (0,0 11) (0,15) (0,11) (0,03) Nonionic surfactant content Sample 12tlL 5.82 0-50 0.29 0.25 0.04 +7.10 (93,2) (0,013) (0,13) (0,1+) (0 ,02) Sample 130.1114% 6.3IQ, 47 0.31 0. 25 0.06 24.30 (101) (0,012) (0,14) (0 ,11) (0,03) Sample 141.68% 6.03 0.50 [1 ,340,250,0935,40(96,6)'(0,013)(0,15 ) (0,11) (0,04) Sample 153.36% 6.22 0.4 8 0.33 0.25 0.08 33.63 (99,6) (0,012) (0,15) (0,11) (0,04) Clay content Sample 16 t, 5.84 0.52 0.37 G, 26 0.11 40.30 (93,4) (0,013) (0,17) (0,12) ( 0,05) Nbuk 17 3.36% 6.16 0.49 0.36 0. 25 0.10 40.30 (98,7) (0,012) (0,16) < 0.11) (0,05) Sample 186.72% 6.21 0.50 0 ．． 48 11.28 0.20 71.30 (99,5) (0,013) ( 0,22) (0,13) (0,09) International search report

Claims (11)

[Claims] (1) At least one porous fiber scrim sheet, mineral wool and light 10-30% wheat flour with residual protein entangled with aggregates. A core containing tart, a small amount of cationic guar bean, and a small amount of non-ionic potassium. Low-density mineral wool foam for structural materials with riethanoxy surfactant/dispersant Nell. (2) The panel according to claim 1, comprising a second scrim sheet. (3) Density is 3 to 10 pounds per cubic foot (approximately 50 to 160 kg/m3) , with a modulus of rupture of at least 60 pounds per square inch (approximately 42,000 kg/m 2) The panel according to claim 1. (4) Contains 0.01-1% trimethylammoniopropyl guar chloride A panel according to claim 1 consisting of: (5) 0.01-3% with a molecular weight of 1000 and 15 ethylene oxide units A special compound containing non-ionic dinolylphenoxyboryl (ethanol tree) and ethanol. A panel according to claim 1. (6) Mineral wool and lightweight aggregates and the viscosity after boiling does not increase significantly 10-3 0% starch and 0.01-1% cationic guar bean and mineral wool and 0.03 to 3% of nonionic polyethanoxy surfactant/dispersant. the process of preparing a diluted aqueous composition and placing it on a moving support wire belt with a porous structure; The fibers and aggregates intertwine to move the composition, forming pores with water-containing pores and voids. The process of creating the structure and applying a vacuum equivalent to 2 to 20 inches of mercury to the structure. A process that destroys pores and dehydrates a structure without substantially destroying the voids in the structure. pressure on the structure corresponding to 5 to 70 inches (0.13 to 1.8 m) in the water column. and simultaneously passing heated dry air through the structure to substantially destroy the voids. A moving support wire belt comprising the steps of further dehydrating and drying the structure without removing water. A method of manufacturing low density mineral wool panels for structural materials. (7) Patent made using wheat starch with residual protein in starch A panel manufacturing method according to claim 6. (8) Using wheat starch with about 6% residual protein in starch A panel manufacturing method according to claim 6. (9) Patent for using trimethylammoniopropyl guar chloride in guar A panel manufacturing method according to claim 6. (10) Nonionic surfactant/dispersant: dinonylphenoxy poly(ethylenexy) )・The panel manufacturing method according to claim 6, which uses ethanol. (11) Ethylene with a molecular weight of about 1000 and about 15 as a nonionic surfactant/dispersant Using dinonyl phenoxy poly(ethyleneoxy)/ethanol with oxide units A panel manufacturing method according to claim 6, which comprises: