JPH0414576Y2 - - Google Patents

Description

[Detailed explanation of the invention] A. Purpose of the invention [Field of industrial application] This invention relates to a ceiling board in which an uneven pattern is provided on the surface of a low-density board formed mainly from mineral fibers such as rock wool and mineral fiber. In particular, the object is to obtain a ceiling board with improved physical properties of the surface of the uneven pattern.

[Conventional technology]

Conventionally, short fibers such as rock wool or mineral wool, water-soluble and water-dispersible binders, fillers, auxiliary agents, etc. are mixed with water to form a paste-like material that can be plastically deformed, and this is then extruded or rolled. It is very common practice to produce relatively low density fiberboards by forming them into plates and drying and curing them.

According to the above-mentioned paste method, by applying a rubbing process to the surface of the plate during molding, a travertine pattern that is close to natural can be imparted, and this travertine pattern ceiling board is manufactured in extremely large quantities.
In order to enhance the design of the plate, pattern-shaped recesses are provided by secondary cutting to create a three-dimensional pattern on the surface.

[Problem that the invention attempts to solve]

Mineral fiber board made by the paste method mentioned above is 0.3-0.5
Due to its low density, sound absorption, heat insulation, fire prevention, and dew prevention properties, it is extremely suitable for ceiling panels.However, after the drying and curing process during normal manufacturing, the front and back surfaces are cut to give a smooth finish. The original plate needs to be a thick plate that takes into account the finishing allowance, and if recesses are to be cut into the surface, it is necessary to increase the thickness to maintain strength. In addition to lowering the yield of raw materials during manufacturing and increasing processing costs such as drying and cutting, the surface of the board is the same soft tissue as the inside and is susceptible to external damage, so the uneven pattern conditions must be extremely limited. It didn't happen.

B. Structure of the invention [Means for solving the problems] The present invention is a mineral fiber ceiling board with an uneven pattern that can solve the above problems.

That is, the present invention has a small binder content of 0.3
On a textured surface on a soft substrate with a uniform density of ~0.5,
A mineral fiber ceiling board with an uneven pattern, characterized in that it has a hard skin layer having a laminated layer with a binder content higher than that of the base, and the area ratio of the concave portions to the convex portions of the patterned surface is 0.8 to 1.2. This is the summary.

In the above, the binder content is small 0.3~0.5
The soft substrate with a density of It is possible to improve the strength of the entire board while reinforcing the uneven pattern, and by setting the area ratio of the concave and convex portions to a range of 0.8 to 1.2, a uniform product with the reinforcing effect balanced as a whole can be obtained. can get.

The ceiling board of the present invention can be obtained by the following manufacturing method using a conventional paste method.

As a starting material for sheet manufacturing, a paste-like material that can be plastically deformed to the extent that it does not naturally flow is used by kneading mineral fibers, water-soluble and water-dispersible binders, fillers, and other auxiliaries with water in the paste method. After forming this into a plate shape by extrusion or rolling, if necessary, the surface is rubbed to form travertine-like surface cracks and small depressions on the surface, and an embossing roller is pressed onto the surface of the plate. , a concave portion and a convex portion having the above-mentioned area ratio are formed. According to this embossing process, a convex portion corresponding to the volume of the recess can be formed without causing excessive local compression due to plastic deformation of the material. Therefore, even if a travertine pattern is provided, the pattern can remain, although it will be deformed to some extent.

This embossed plate is then subjected to the next drying process (usually in a hot air circulation drying room at 130 to 190°C, drying for 3 to 10 hours depending on the thickness of the plate)
As water evaporates from the surface as it dries, the aqueous binder is mainly transferred to the surface, forming a hard skin layer with a high binder content, usually less than 1 mm in thickness, on the embossed uneven pattern surface. is formed to obtain the product of the present invention.

[Effect]

As mentioned above, the ceiling board of the present invention is composed of a low-density base layer with a hard skin layer with a high binder content that is integrally laminated and bonded to the entire surface of the uneven pattern, so it suppresses the decrease in strength due to uneven molding. At the same time, the hardness and strength of the surface of the pattern can be improved, the degree of freedom in pattern selection conditions can be expanded, and it is possible to achieve excellent design properties as well as performance such as sound absorption, heat insulation, fire prevention, moisture absorption, and stain resistance.

〔Example〕

Embodiments of the present invention will be described with reference to the drawings.

Figure 1 is a plan view of the ceiling board, Figure 2 is Figure 1 AA
FIG. 3 is a schematic side view of the apparatus for explaining its manufacturing method.

In Figures 1 and 2, 1 is a substantially homogeneous soft substrate with a density of 0.4 obtained by a paste method in which short rock wool fibers and other additives are fixed together with a binder; It is an uneven patterned surface formed by the formed concave portions 4 and convex portions 5, and 3 is a hard skin layer with a higher binder content than the soft substrate 1 laminated on the entire surface of the uneven patterned surface 2. be. The concave portion 4 and the convex portion 5 have a width of 15 mm, as shown in FIG.
mm linear recesses 4 are arranged in an orthogonal grid pattern with a pitch of 50mm, and the area surrounded by the recesses 4 is 35×35mm.
The square convex portion 5 is formed so that the depth of the concave portion 4 is 10 mm.

The surface area ratio occupied by the concave portions 4 and the convex portions 5 is approximately 1.

The thickness of the hard skin layer 3 was approximately 0.9 mm on the top surface of the convex portion 5 and approximately 0.6 mm on the bottom surface of the concave portion 4.

The above ceiling board can be obtained by the following manufacturing method.

Raw material paste composition for sheet forming (weight basis) Granular rock wool short fibers 100 parts Vegetable gum 0.7 Starch 10 Calcium carbonate powder 15 Kaolin clay 15 Paraffin wax 0.2 Water 300 The above composition was kneaded under heating at 80°C, A plastically deformable aqueous paste that does not naturally flow is prepared, and as shown in FIG.
18mm thick plate 20, 10m/
It is continuously extruded onto a belt conveyor 11 at a speed of 30 minutes, and a square concave portion having a diameter of 30 cm is formed, which is located 30 cm from the extrusion port and matches the uneven pattern surface 2.
The embossing roller 12 with a diameter of 1.5 cm was processed with a concave-convex pattern at a surface speed matching that of the conveyor, cut into required dimensions, and then dried in a hot air drying oven 13 at 140° C. for 8 hours to obtain the above-mentioned product.

Surface hardness of the product (measured according to JISZ-2117)
and bending strength (measured according to JISA-1408) were as follows.

The comparative example corresponds to a conventional product in which a plate with the same composition as above was made and dried using a paste method, and then an uneven pattern having substantially the same dimensional conditions was formed by cutting.

Example product Comparative example Hardness (Kg/mm ² ) 0.24 0.11 Bending strength (Kg/cm ² ) From the front 13.2 9.1 From the back 14.8 10.3 Furthermore, this example product was subjected to a fire protection test in a 750℃ heating furnace according to JISA-1321. When I went to
The temperature inside the furnace was 795°C, and it was confirmed that the fire prevention performance was sufficient.

C. Effect of the invention As explained above, the surface hardness and strength of the uneven patterned mineral fiber ceiling board of the present invention are extremely superior to those formed with an uneven pattern using the conventional cutting method, so the board thickness can be reduced. It is possible to reduce the weight and reduce the risk of damage and breakage, making it easier to handle.
In addition, the manufacturing process does not require secondary machining, does not generate chips, and eliminates waste of time and materials, resulting in practical effects such as a reduction in manufacturing costs.

[Brief explanation of the drawing]

The drawings show an embodiment, and FIG. 1 is a plan view, FIG. 2 is an enlarged sectional view taken along line AA in FIG. 1, and FIG. 3 is a schematic side view of the apparatus for explaining the manufacturing method. DESCRIPTION OF SYMBOLS 1... Soft base, 2... Concave-convex pattern surface, 3... Hard skin layer, 4... Concave portion, 5... Convex portion.

Claims (1)

[Scope of utility model registration request] In a ceiling board manufactured by embossing a plate of a plastically deformable paste made of mineral fibers, an aqueous binder, and other additives to form an uneven surface pattern and drying and hardening, the binder content is A hard skin layer 3 having a binder content higher than that of the soft substrate 1 is laminated on a concavo-convex pattern surface 2 on a soft base 1 having a small density of 0.3 to 0.5; A mineral fiber ceiling board with an uneven pattern, characterized in that the area ratio of the portion 5 is 0.8 to 1.2.