JPH03221440A - Inorganic fiber molded board and manufacture thereof - Google Patents

Abstract

PURPOSE:To improve the surface hardenability, surface smoothness, and stiffness by putting in superposed relation the mat base material of an inorganic fiber containing an uncured binder and the high density molded board of inorganic fiber molded higher in density than the mat base material, and then integrating both of them by hot press. CONSTITUTION:During manufacturing of rock fiber, water soluble phenol resin is sprayed and adhered thereto as a binder at the same time of fiber forming, and on a belt conveyer, a raw fiber mat 4 in which rock fibers are gathered into a mat shape is manufactured. In the next place, on the lower mold 2 of a hot press unit 1, a serrated mold 3 is mounted, and then the raw fiber mat 4 is set thereon by leaving the state of fiber arrangement as it is, and further the mat is subjected to hot press molding, thereby obtaining a high density molded board 7 with serration in its one surface. Next, on the same hot press unit 1, another cutout raw fiber mat 4 is set as a mat base material, and a preliminarily high density molded board is put thereon downwardly in the form of allowing the molded surface with serration to be in contact with the mat raw material, and then they are hot press molded to be a predetermined thickness as a synthetic molded board. In this manner, an inorganic fibrous molded board 6 formed by integrating both of them can hold a significant adhesive strength.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to an inorganic fibrous molded board used as ceiling material, wall material, etc. of buildings, and a method for manufacturing the same.

[Conventional technology]

BACKGROUND ART Conventionally, molded plates made by heating and curing inorganic fibers such as rock wool and glass wool have been widely used as building materials characterized by heat insulation, sound absorption, and nonflammability. These inorganic fibrous molded plates are made by spraying and adhering a water-soluble thermosetting resin binder such as phenol resin, melamine resin, or urea resin to inorganic fibers such as rock wool or glass wool at the same time as fiberization, and then attaching them onto a belt conveyor. It is manufactured by collecting cotton into a mat shape and subsequently passing it through a hot curing furnace.

By the way, the density of the inorganic fibrous molded plate obtained as described above can be arbitrarily selected from a wide density range of 30 to 250 kg/m' by adjusting the MA speed, conveyor speed, etc. Since the fiber length is relatively long, it is possible to obtain a product with excellent handling properties, but in consideration of workability, a product with a density in the range of 80 to 150 kg/m3 is usually used.

However, materials in this density range have soft surfaces that do not adhere well to surface decorative materials, or have insufficient surface strength to be used in areas that are touched by humans, such as wall materials, or have poor surface smoothness. It was also not sufficient in that respect.

Therefore, attempts have been made to improve the surface smoothness, surface hardness, and rigidity of inorganic fibers such as rock wool and glass wool while maintaining their good handling and workability properties.

For example, Japanese Patent Publication No. 51-38351 and Japanese Patent Publication No. 51-38351
Publication No. 6-13623 discloses s containing an uncured binder.
An inorganic fiber with a specific gravity gradient formed by a method consisting of a surface curing process in which M&Ma mat is compressed to a thinner thickness than the desired thickness and then heated, and a finishing process in which the product is held and heated to the desired product thickness. The board is listed and also
In Japanese Patent Publication No. 52-46992, there is a three-stage density gradient of the maximum density layer, the minimum density layer and the intermediate density layer,
An inorganic fiberboard is disclosed that has a good cushioning effect and improved surface hardness and surface workability without impairing lightweight properties by forming a minimum density layer in the middle.

(Problem to be Solved by the Invention) However, although these S bran fiberboards are effective in improving the surface hardness to some extent, they are first highly compressed to form a high-density surface layer, and then After expanding using the elastic restoring force of the uncured intermediate portion, the intermediate portion is compressively hardened, so if the thickness of the surface layer is increased in an attempt to obtain sufficient surface hardness, the bonding of the intermediate portion may occur. When the agent is in a semi-cured state and the intermediate part is compressed and hardened while maintaining the final product thickness at a predetermined thickness, the desired bonding force does not appear in the intermediate part and it tends to peel off along the thickness direction. There were problems such as it becoming a thing.

[Means to solve the problem]

The present invention was developed through research to solve the above-mentioned problems, and an inorganic fibrous molded board consisting of a two-layer structure of a low-density molded layer and a high-density molded layer has good surface hardening properties, surface smoothness, and rigidity. We discovered that the mat base material of inorganic fibers containing an uncured binder and a high-density molded board of inorganic fibers molded to a higher density than the mat base material are layered together, and the manufacturing method is to overlap both. The present invention was completed based on the discovery that an inorganic fibrous molded plate having a two-layer structure in which a low-density molded layer and a high-density molded layer are firmly bonded can be obtained by hot-pressing and integrating them.

That is, the present invention provides a so-called raw wool mat, which is made by spraying and adhering a binder to S quality fibers such as glass wool, rock wool, and ceramic fibers at the same time as fiberization, and collecting the fibers in a mat shape on a conveyor. It is used as a base material for the low-density layer, and a high-density molded plate of inorganic fiber that has been previously molded to a high density is superimposed on this, and both are hot-pressed to form a low-density molded layer and a high-density molded layer. An inorganic fibrous molded plate having a two-layer structure is obtained.

The present invention will be explained in detail below.

The raw wool mat made of the above-mentioned inorganic fibers is also used as the mat base material and the high-density molded plate in the present invention, but both of these raw wool mats may be of the same type. Separate binder resins with different types and amounts of binder resins, fiber orientations, etc. may be used.

The uncured binder contained in the mat base material includes thermosetting resins such as phenol resin, urea resin, and Melakun resin, vinyl acetate-based emulsions, acrylic ester-based emulsions, and rubbers such as SBR and NBR. Although latexes and mixtures thereof can be selected, from the viewpoint of developing strength of the matte base material after curing, phenol resins or mixtures of phenol resins and the above-mentioned resins or rubber latexes are preferred. The content of the binder is 0.5 to 10% by weight as a solid content per fiber weight, depending on the density after molding and the properties of the binder.
A range of is preferred. That is, if the amount of the binder is less than 0.5%, sufficient molding strength will not be developed, and if it exceeds 10%, the nonflammability will be impaired, which is not preferable.

In the process of hot-pressing raw wool mats, the heating temperature and holding time are the same as when forming a high-density molded plate.
Alternatively, when hot-press molding a high-density molded plate and a mat base material together, the heating temperature may vary depending on the type and amount of binder, the thickness of the raw wool mat, density, etc., but the heating temperature is 150'C to 2.
A suitable holding time for 50'C1 is 5 to 20 minutes.

First, when forming a high-density molded plate by hot pressing, we not only select the density and thickness arbitrarily, but also improve the bonding strength with the matte base material and the inorganic fiber cone composite with the matte base material. One of the characteristics is that the shape of the molded plate is determined in order to give it rigidity, handling properties, and side workability. To give a specific shape, after forming a thick high-density molded plate, process it with a cutting device such as a cutter sander, or make effective use of the flexible molding part of the mat base material to form the desired shape. A method of forming a different shape using a mold is simple and effective in terms of process.

For example, in order to increase the bonding strength with the low-density molded layer, the bonding surface of the high-density molded plate with the matte base material may be formed into a serrated shape, or in addition to the serrated bonded surface, the matte base material may be The rigidity of the composite can be further improved by covering the side part with a high-density molded plate, and by increasing the density of the side part, actual processing of the side part becomes possible. As mentioned above, it is not necessary to uniformly overlap the high-density molded plate over the entire surface of the mat base material, and by adjusting the wiring of the raw wool mat, the density of the high-density molded plate itself can be partially changed. be able to.

When hot-pressing a matte base material and a high-density molded plate at the same time, sufficient bonding is usually achieved without applying special adhesive to the interface, but if the matte base material contains a binder of 2% by weight or less, When the quantity is small or the density of the high-density molded plate is 350
kg/m' or when the density of the low density layer corresponding to the matte base material after composite is 60 kg/m
If it is less than 3, the bonding may be insufficient depending on the cross-sectional shape. Therefore, in such cases or when severe handling is expected, use thermoplastic adhesives, thermosetting adhesives, rubber adhesives, etc. commonly used for the interface on the high-density molded plate side or the interface on the matte substrate side. It is preferable to apply or spray it.

When performing hot pressing, it is not necessarily necessary to place a high-density molded plate on the matte base material, and it may be more effective to stack the matte base material on the high-density molded plate.

The density ranges of the high-density molded layer and the low-density molded layer of the hot-pressed composite molded plate are relative and are not particularly limited, but the range of densities of the high-density molded layer and the low-density molded layer of the hot-pressed composite molded plate is relative and is not particularly limited. If maintenance is important, the density of the high-density molding layer is 200~200, depending on the thickness of the high-density molding layer and the low-density molding layer.
Range of 500 kg/m3, density of low density molding layer is 40~
A range of 120 kg/m3 is suitable. However, this does not apply when particularly high surface hardness is required or when further lightweightness is desired.

When the composite molded plate of the present invention consisting of a high-density molded layer and a low-density molded layer is covered with various decorative surface materials and used as a building material, it is not necessarily necessary to use the surface with excellent surface hardness on the front side, for example, as a ceiling material. In areas that are not touched by human hands, by using a low-density molded layer on the front side, it is possible to improve the sound absorption properties of the low-density molded layer and the sound insulation properties of the high-density molded layer on the back side. It can also be used as a building material with excellent deflection resistance.

The present invention will be explained in detail below.

Example 1 At the time of cotton wool making, a water-soluble phenol resin (phenol resin adhesion amount is 2.0% by weight based on the weight of rock wool) was sprayed and applied as a binder at the same time as fiberization, and was applied on a belt conveyor. A raw wool mat was obtained by collecting the cotton into a mat shape.

Lower mold 2 of the steam heating type hot press device 1 shown in FIG.
Sawtooth mold 3 on top (size W 350xL650mm
), set a 430g raw wool mat 4 on top of this with the wiring state maintained, hot press molded with the upper die 5 so that the maximum thickness is 10 mm, and made a dense mat with a sawtooth shape on one side. A high-density molded plate of 250 kg/m3 was obtained. The heating temperature was iso'c for the upper surface of the press, 200° C. for the lower surface of the press, and the heating time was 10 minutes. Next, on the same hot press equipment 1, size? 11350x L650 (
Set 370 g of the above-mentioned raw wool mat cut out to a size of mm) to serve as a mat base material, and stack the above-mentioned pre-formed high-density molded plate facing downward so that the sawtooth-shaped bottom surface is in contact with the mat base material to form a composite molded plate. The thickness of the binding is 30mm
Hot press molded to give the following. The heating temperature was 1806C for the upper surface of the press and 200'C for the lower surface of the press, and the heating time was 10 minutes.

The inorganic fibrous molded plate 6 in which the two are integrated in this way is the second
As shown in the figure, since the high-density molded layer 7 and the low-density molded layer 8 are joined by sawtooth surfaces, the contact area is large, and a high bonding strength can be maintained between them. The overall average density was approximately 115 kg/m3.

Embodiment 2 A steam heating type hot press apparatus 1 shown in FIG. 3 includes a lower mold 2 having a sawtooth mold 3 and a side wall portion 6 . Then, 920 g of the raw wool mat 4 produced in Example 1 was placed in this mold so as to have a uniform density distribution, and hot press molded using the upper mold 5 to give an open mold thickness of 30 mm.
A high-density molded plate with a density of 250 kg/m3 was obtained. Next, this high-density molded plate is attached to the lower mold 2 from which the sawtooth mold 3 is removed.
The mat was set with the recess facing upward, and 370 g of the raw wool mat of Example 1 was uniformly distributed in the recess of the high-density molded plate as a mat base material, and then hot press molded using the upper die 5, as shown in Fig. 4. As shown, an inorganic fibrous molded plate 6 is obtained which integrally has a high-density molded layer 7 with high-density side parts 10 of 50 mm width formed on both sides and a low-density molded layer 8 formed in the recessed part. Ta. Note that hot pressing was performed under the same conditions as in Example 1.

This inorganic fiber molded board 6 has a size of W450 x L6.
00x T2O (mm), the overall average density is about 150
kg/m'.

〔Effect of the invention〕

As explained above, the inorganic fiber molded board according to the present invention is lightweight because it has a two-layer structure of a low-density molded layer and a high-density molded layer, and has good handling properties and workability that inorganic fibers have. It was possible to improve the surface smoothness, surface hardness, and rigidity while maintaining the

Furthermore, according to the method for manufacturing an inorganic TA fiber molded plate according to the present invention, a high-density molded plate is formed in advance, and this is superimposed on a matte base material forming a low-density molded layer and integrally formed by hot pressing. Because of this, the density ratio, shape, and thickness of the high-density molded layer to the low-density molded layer can be freely designed, and the adhesive strength between the high-density layer and the low-density layer can be increased, making it possible to improve the structure of buildings. It is extremely useful as a method for manufacturing inorganic fiber molded plates used for walls, ceilings, etc.

[Brief explanation of drawings]

Fig. 1 is a front view of a hot press device used in carrying out the present invention, Fig. 2 is a sectional view showing an embodiment of an inorganic fibrous molded plate according to the present invention, and Fig. 3 is a front view of a hot press device used in carrying out the present invention. FIG. 4 is a front view showing a hot press apparatus, and FIG. 4 is a sectional view showing another embodiment of the inorganic fibrous molded plate according to the present invention. l...Hot press device 4...Raw wool Matsutoro...Inorganic fibrous molded plate 7...High density molded layer 8...Low density molded layer

Claims (2)

[Claims] (1) An inorganic fibrous molded board consisting of a two-layer structure of a low-density molded layer and a high-density molded layer. (2) A mat base material of inorganic fibers containing an uncured binder and a high-density molded plate of inorganic fibers molded to a higher density than the mat base material are overlapped, and both are integrated by hot pressing to reduce the density. A method for manufacturing an inorganic fiber molded board comprising a molded layer and a high-density molded layer.