JPH06504002A - Insulating material manufacturing method and device - 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] □”□】□□ The present invention relates to a method and apparatus for manufacturing an insulating material, and a method and an apparatus for manufacturing an insulating material. With respect to shredded insulating materials, particularly, but not exclusively, shredded materials and Combination of +1 efibrillated and non-fibrillated cellulose fiber materials an insulating material, preferably in the form of a batt, manufactured from The present invention relates to a method and apparatus for manufacturing.

The thermal insulating and sound-dampening properties of cellulosic materials are well known, and the use of such materials is It is known that it can be used as a border material. Insulating materials such as The advantage of using it as a material is that it takes waste materials, such as newspaper, out of the waste stream and turns them into useful products. It is possible to recirculate it to make it possible. Cellulose material as insulation material The disadvantage of using these materials is that they are flame retardant, preferably resistant to insects, pests and corrosion. This is something that must be processed in order to make it more sexual. Newspaper-like paper It is known to treat ululose materials with flame retardant compounds such as borax.

There is a need to make effective use of waste. Waste paper and other cellulose fiber materials , their inherent insulating properties, and their potential for various products including insulating materials. Recognized as a resource material. Until today, such waste has been harmful to the environment. 　　　　　　　　　　　　　　　　　　　　　　　　　　　　 is Acceptable promising materials that are not susceptible to hazards or deterioration that would reduce their usefulness. There has been a lack of an economical way to convert.

Cellulose fibers from waste paper or other cellulosic materials have hitherto been used as insulation materials. However, this was done in a very limited manner. Manufacture is special It has been limited to highly filled products requiring unique application methods and equipment. That's it In its untreated state, the material is extremely sensitive to moisture and suffers from long-term deterioration problems. It's here.

Mineral fiber insulation materials have brittle properties, and when subjected to mechanical stress, they deteriorate and break, resulting in microscopic damage. It is released into the environment in the form of fine mineral particles and tends to cause unknown health problems.

Therefore, replacing mineral fiber insulation materials with insulation materials that pose less of a risk to the health of the aircraft. There is a need.

Various proposals have been given for utilizing cellulosic waste to produce insulating materials. It's here. British Patent No. 1,359.996 discloses that shredded paper is Two outer panels suitably treated with flame retardant materials such as ammonium and ammonium sulfate. An insulating material is described that consists of sandwiched between two sheets of paper facing each other. They are opposed to each other. A hole is punched in at least one side of the paper. That paper facing outward is shredded. By spraying the paper with a suitable binder or adhesive and then covering it with the opposing paper. Can be combined with more shredded paper. Apply pressure to the sandwich The material may be used to better bind the shredded paper to its outer counterpart. is specially recognized as an insulating material designed primarily as a soundproofing material with thermal insulation properties. has been established. The product may be stored in rolls or insulated in convenient sizes. It can be cut and stored in a vat.

Aus I. Laria Patent Nos. 527.843 and 540. The H2 specification contains the following A method for forming a hat made by combining synthetic fibers and wool fibers such as I) is described. It is listed. That is, it: crushes, combs, or otherwise draws the m-fiber mixture. to form randomly dispersed slivers of fibers.

The sliver is then passed through a folding device to form a matrix of desired thickness.

The mat is then sprayed with a mixture of fire-resistant resin, smoke suppressant, and insecticide and cured. , if desired, cut into appropriately shaped batts.

The present invention aims to solve the problems of conventional batts or insulation materials. and provide safe and effective insulation materials, such as batts or insulation materials. The object is to provide a method and apparatus for manufacturing the material.

The present invention provides varying degrees of fire protection by varying the density of the cellulosic material. cellulose fiber absolute that can be manufactured to be durable, weather resistant, and corrosion resistant. The dual purpose of this invention is to provide a method for manufacturing edge materials. The present invention provides a cell having the above properties. It is also an object to provide a loin fiber insulation material.

Accordingly, the present invention provides, in one aspect, a shredded cellulose fibrous material and The shredded material is coated with a hard or non-hard binder to form a coated shredded material that is non-fibrillated. Shredded cellulose material is introduced onto and into the coated shredded material and filled. applying a material, and pressing and hardening the filled shredded material to bond the material with the binder. an open cellulose fiber insulation material comprising: forming a cellulose fiber insulation material; provides a method for manufacturing the material.

Preferably the binder consists of a thermosetting resin material, which is additionally treated with fungicides and insecticides. contain additives and/or flame retardant chemicals. The binder is applied to the shredded material by spraying. It is preferable to use

Preferably, the additional binder is applied to the filled shredded material before pressing and curing.

The shredded material is carded or combed and then loosely leveled by applying a binder. It is preferred to provide a uniformly formed layer of material to facilitate the introduction of non-fibrillated material. .

The binder includes a crosslinked thermosetting flexible polymeric material that has elastic recovery properties and It is preferred to provide a cellulosic fiber insulation material that has strength and flexibility.

Suitable polymeric materials contained in the binder include polymers, copolymers, modified polymers, polymers, etc. Kryl, modified acrylic, PVA, urea formaldehyde resin, phenol phorol formaldehyde, resorcinol formaldehyde, melamine formaldehyde, and urethane. The polymeric material is cellulosic, as is known in the art. Thickening agent (carboxy methyl cellulose, hydroxyethyl cellulose, hydro Thickening agents such as xymethylcellulose, and any admixtures thereof), casein May be used with , wheat flour, and cornflour5 The flame retardant chemical may be selected from any known flame retardant chemicals, but Preference is given to selecting highly hydrated inorganic chemicals such as sand, hydrated alumina, etc. Yes.

Examples of flame retardant materials that can be used alone or in combination are calcium carbonate, sulfuric acid Calcium, calcium silicate, aluminum trihydrate, boric acid, borax, ammonium phosphate ammonium polyphosphate, potassium aluminum sulfate, magnesium chloride, Magnesium phosphate, sodium silicate, potassium silicate, metaborate, chlorinated acrylic It is a chlorinated wax.

Not all polymeric materials are compatible with the flame retardant substances suggested; Appropriate testing is required to determine the compatibility or otherwise of the flame retardant/flame retardant combination. Those skilled in the art will recognize that this may occur. For example, sodium silicate and Potassium, acidic polymer and acrylic, ammonium polyphosphate and alkaline polymerization Body: Cellulose thickeners and acidic flame retardant chemicals are known to be incompatible. Up In addition to the above, it is well known that cellulose fibers and most flame retardants contain nutrients. As such, consideration must be given to effective insecticides and biocides. stomach. Microorganisms become more likely to attach to these nutrients. Cellulose fibers are harmful to insects and urine It's more edible.

Therefore, if the high humidity continues or if the cellulose fibers become damp due to other reasons. Sometimes, without a suitable biocide, cellulose fiber insulation materials can quickly become moldy and deteriorate. begins to change. Suitable biocides, insecticides, or pesticides of low toxicity and safe for consumers and the environment. Preferably, a rodenticide is incorporated into the formulation. Biocides and insecticides are binder compositions must be compatible with The following are examples of acceptable biocides: Busan 1009 (trade name), Busan T CMTB (trade name), Ka KathonH (trade name), Acrylic (Densil) (trade name), Kosai Kocide (trade name), and insecticide: Peregin, Permethrin, Biosieth rin), boron compounds, butane 111 (trade name), butane 11” (trade name), and is a combination of them.

A preferred fungicide, insecticide, and bactericide substance is thiocyanomethylbenza Thiazole, catone, acrylic, metaborate, birethro id), borax, and other boron compounds. Disinfectant and bactericide chemicals are Of course, depending on the specific binder used, it is substantially stable at process curing temperatures of around 150°C. It should be.

The above binder is a dry flame retardant that is incorporated during the production of non-fibrillarized cellulose materials. The drying agent must be compatible and/or preferably synergistic with Dried flame retardants are obtained when paper or other cellulosic materials are crushed or milled. This is necessary because powders can form explosive mixtures with air, and therefore During the production of fibrillated cellulose materials, it is not safe to apply flame retardants. It's necessary. Dry flame retardants can be selected from the following materials as examples: : ammonium fJ acid, ammonium polyphosphate, barium metaborate, chlorinated wax aluminum trihydrate, borax, boric acid, calcium carbonate, magnesium chloride, phosphorus Magnesium acid, barium metaborate, barium sulfide, barium phosphate, oxychloride Antimony, antimony trioxide, calcium sulfate, calcium silicate, sodium silicate aluminum, potassium silicate, potassium aluminum sulfate, or any combination thereof.

Particularly preferred flame retardants are: Ammonium phosphate, aluminum trihydrate, ammonium phosphate, chlorinated wax , borax, barium metaborate, ammonium polyphosphate, and magnesium chloride.

Before pressing and curing, the material is placed between scrims with spikes. Distribute it evenly with a comb roller and comb, and remove the About 50cm tall? It is preferable to pass through a compression step of compressing to o. pressed material , cut into batts for roof or wall insulation or blankets or empty, e.g. Cut into strips for wrapping around the duct. For example, the band is 1oOu+ It may be formed to have a certain thickness. The bameth produced in this way has a similar Has thermal insulation properties equal to or better than that of fiberglass batts of thickness and even better. It has tear strength and does not pose the environmental and safety issues of fiberglass batts.

25iz to 100 in various densities to provide the necessary heat resistance for any particular purpose. It is possible to form a strip with a thickness of The 25zx strip, which has better thermal insulation properties, is due to the flexibility and elasticity of the material. You can wrap the obi around it.

In a preferred embodiment, the shredded cellulose fibrous material is shredded waste paper. use Other cellulose or cellulosic materials that can be used include shredded straw from wheat, rice, etc. , Shredded book shavings.

As preferred FfQ-like, non-fibrillated cellulosic materials make the material small and Non-fibrillated, e.g. processed in a hammer mill to give a fine fluffy material recycled paper or cardboard waste. Similarly, other cellulose or can be formed using non-fibrillarized materials using cellulosic materials . For example, other cellulose or cellulosic materials that can be used include waste natural It is a fibrous or textile material.

Before incorporating the waste cellulosic material into the product or carrying out the method of the invention There is no need to perform ink removal, etc., or similar treatments.

In a particularly preferred embodiment of the invention, the product comprises shredded and non-fibrillated cellulose. Contains materials in a weight ratio of approximately 20:80. The binder is preferably combined 5 to 25 parts by weight (II also preferably 10 to .20 parts by weight) of cellulosic material Add to the material within the range.

In one embodiment, the present invention provides a uniform distribution of shredded cellulose material. means for forming a non-fibrillated cellulose material in the shredded cellulose material; means for introducing, means for providing a covering sheet of cellulosic material on each surface of the ma soto; The shredded cellulose material and the cover sheet are bonded together to form a bonded insulating material. and means for introducing a binder into the shredded cellulose and the covering sheet to achieve Made of insulating material, consisting of equipment for producing Sandiso Chiaki cellulose insulating material Provide construction equipment. Preferably, the shredded cellulose material is provided from a shredder. evenly Hand cutting to form a distributed shredded cellulose material spreads the shredded material and disperses it. and preferably includes a conveyor mechanism to form a mantle of evenly distributed shredded material. Delicious.

The conveyor mechanism is a chain member that extends from the shredder to spread and disperse the shredded material. Preferably, the chain includes a plurality of chain members having chain members.

The device further facilitates distributing the non-fibrillarized material within the shredded material. : It is preferable to have an air injection means. The device is a hardener that cures bonded insulating materials. It is preferable to include means for converting.

Preferred embodiments of the device and method according to the invention will now be described with reference to the drawings. figure During, FIG. 1 is a schematic elevational view of a device according to the invention.

FIG. 2 is a plan view of the spreader of the device.

FIG. 3 is a cross-sectional view of the pulverized material introduction mechanism of the device, and FIG. 4 is a process diagram schematically illustrating a preferred method of the present invention.

With regard to FIGS. 1 to 3 of the drawings, there is shown an upper sheet feeder 20 and a lower sheet feeder 20. Feeding machine 21, shredding machine It, spreader 12, conveyor 13, non-fibrillation material material feeder 14, air injector 15, binder sprayer 16, 17, and 18, and curing A device 10 is shown with a tunnel I9. Waste paper is transferred to conveyor 22. and supplied to the shredding machine 11. The shredded semi-pressed paper 23 that has come out from the shredder 11 is spun It is spread on redder 12, combed, and sent to conveyor 13.

Placed on top of the formula spreader 12 with thin spring tyne Further shredded material is layered onto the chain bed using a rotary drum (not shown). It may be distributed uniformly.

Where the shredded material exits the chain bed, there are two rows of air holes (not shown) below the edge of the chain bed. The resulting mat of shredded cellulose material is blown into a chain base by blowing low pressure air into the 13 and onto the conveyor 13 for further processing. may help maintain its shape while passing through.

The ram placed in the casting bed and rotated 1< The diameter may be 1 to 1000 iz, and the preferred diameter is I; Oiz. Kubling record may have a length of 50zz to 200zz, with a preferred length of 1 lozz. de There are 20 teeth or 200 teeth evenly distributed around the surface of the ram. The preferred number is 90 teeth.

Spread it! Then, spray the shavings supplied by the sprayer 16 onto the combed shredded material 24. . The sprayed shredded material passes through 5 non-fibrillarized material feeders + 4 (D~1 feeders). where the non-fibrillated material (e.g. fine fluffy crushed waste paper or board) is paper) is fed into the shredded material from the DM feeder.

Immediately after the DM feeder, the shredded material is injected with compressed air from an air injector 15 or jet to disperse the non-fibrillarized material substantially uniformly into the shredded material. .

The binder supplied by the sprayer 17 is sprayed on the inside of the lower sheet 25, and the upper sheet is similarly sprayed. The inside of the side sheet 26 is sprayed with the binder supplied by the sprayer 18 . upper side The lower sheet is brought into contact with the shredded material and squeezed in the dark on a hot plate 17 for curing. It hardens in tunnel 19. Next, sandwich material 3, batt or band if necessary. Can be cut into shaped materials.

Spray goo 12 spreads from the outlet of Shredder II+ to the width of conveyor 13. It has a series of strands 28 going forward. As chain 28 spreads out, additional chains 2 are added in places. 9. Insert the 10 to keep the expanded carded shreds properly supported. each of the chains Each is equipped with spikes 34, which have a height of, for example, 75mm-140zz. They may be held at the same height, or they may all be at the same height. The preferred height is 110u.

This spike may be attached to each node of the chain, or one every 20 nodes. It's okay. The preferred number is one for every five verses.

When you extrude shredded paper onto these spiked chains, the spiked chains separate from the shredder. The strands separate from each other as they pass through the paper, thereby combing the shredded paper. This will spread it across the entire width of the spreader.

The sprayed shredded material is then fed into two DM supplies! Pass through fi+4, where cellulose Fluff is injected into the sprayed shredded material. those hairs are The powder is ground or milled and blown into the gutter 29 by a blower. these The gutter has a series of partition plates 30, each at an angle of approximately 60° to the direction of the axis 31. The left side of the center slopes to the left, and the right side of the center slopes to the right (see Figure 2). as shown).

The DM feeder further includes a buffer plate 33, which blows air into the feeder by means not shown. Direct the loaded non-fibrillarized material toward the partition plate.

The partition plate, which rotates on an axis located in the center of the gutter, distributes hair evenly along its length. and helps to push those hairs through the bottom 32 of the gutter. Hair has uniform density It is extruded as a lump.

This extruded mass passes close to the shredded paper and passes through a number of ( A series of air slugs injected by a high pressure air injector 15 of approximately 175 ) into and around the shredded paper. These nozzles are used at different times Inject the air slug at intervals and pressures to achieve maximum penetration and density of hair into the shredded material. achieve.

The air slug may last from 1/100 seconds to 1 second, but is preferably 1/10 seconds. It has a duration of seconds to 1/2 seconds.

The air slug is controlled by a series of solenoid valves and they shred the filling material Designed to cover the entire width and depth of the

This mat then passes through two diaphragms 32 to further improve the distribution of hair in the shredded material. let

Preferably, the shredded material is shredded newspaper or shredded books or computer paper. However, any suitable cellulosic material may be used. Non-fibrillated materials are preferred is cardboard or other waste cellulosic material, which is ground or milled to Form into a pulverized non-fibrillated hair-like material. Non-fibrillated material is sugarcane Cellulosic waste such as bean slag, straw, rice husks, bean nut pods, coconut husks, etc. It can be made from things.

The device of the invention therefore comprises two sheets of material joined by a suitable bonding agent. It produces a filler with shredded cellulose material sandwiched in between, which has visibility and elasticity. An appropriately sized insulating batt or flexible insulating material for wrapping pipes, conduits, etc. It can be cut into strips of material. Sheet materials include paper, plastic film, and aluminum. Any suitable sheet material may be used, such as minium film or the like.

The top surface of the filled shredded cellulose material treated with a binder is removed as desired before the binder hardens. Omit the upper sheet material as long as it is sufficiently dry before pressing the batt to a thickness of can do.

Referring to Figure 4, there is shown a process diagram schematically illustrating a preferred method according to the invention. It is.

The shredded waste paper is transported from the storage section 41 and combed with a card or comb at a location 43 to remove the shredded waste. Distribute evenly. The binder from storage tank 44 is added to the shredded waste at location 45 and then is then transported to location 46 where non-fibrillated waste paper is added from storage tank 42.

Further binder is added at location 48 and the material is sandwiched between the scrims and compressed at location 49, hardened. It is transported to a cutting place 50 and finally cut into the required bat or band size at a cutting place 51. do.

Examples of preferred binder formulations for use in the process of the invention Phenol Formaldehyde De resin 5 Acrylic resin (ICI DP+05>20 p-toluenesulfonic acid (PTSA) ) Monomagnesium chloride 30 Busan 1009 1 Permethrin 0.5 Water until +00 Meramishi formaldehyde resin 5 Polymer 20 P T S A 1 Boric acid 18 Borax 18 Polymer Joncryl 554 25 Aluminum trihydrate 15 QR7011 (thickening agent) ■ Chlorinated wax 6 Water until it reaches 100 flood Polymer Joncryl 53g 25 Borax 18 Boric acid 18 Chlorine fissure, lx, acrylic polymer 25 ammonium phosphate 30 Busan II"22 Busan 1009 1 Cellulose thickener 2 Water until it reaches 100 Last year's mutual Chlorinated wax/acrylic polymer 25 Ammonium polyphosphate 30 Katong 0.5 Borax 2 Cellulose thickener 2 Water until it reaches 100 Yesterday 1 Modified acrylic (Joncryl + 42L P) 25 Tri-aqueous phase aluminum 28 QR70g (thickener) 2 Water until it reaches 100 prefecture Modified acrylic [Duramol 695] 25 ammonium phosphate 25 QR708 (Thickener) l glycol 1 Busan 1009 1 Chlorinated wax 6 Busan 11" 1 Water until 1004 minutes seven HALof lex () Ialof lex) polymer HF202 (ICI) 25 Ammonium phosphate 30 Cellulose thickening 2 Water until +00 1 plate Acrylic polymer DURAMOL 641) 25 Ammonium polyphosphate 20 Chlorinated wax 2 Cellulose thickener 2 Water until it reaches 100 Calcium carbonate 30 Cellulose thickener 2 Densil 0.5 TCM TB 0.5 Water until +00 Takumi■ Polymer Rhoplex HA 16 25 Magnesium Chloride 30 Permethrin 0.5 QR708 (Thickener) 2 Kocide 0.5 Water until +00 death Haloflex polymer HF202 (ICI) 25 Calcium carbonate 30 QR7082 Busan II" 2 Busan 1009 1 Water until +00 Mackerel] Polymer voncryl 530 25 Magnesium Potassium Sulfate 　30 TT 615 (thickening agent) 2 TCMT8 1.5 Pyosmethrin 0.5 Water until it reaches 100 Salmon dumplings Hydroxyethyl cellulose 10 Calcium sulfate 30 flour Busan 1ilQ9 1.5 Beregin 0.5 Water until it reaches 100 [ Carboxymethyl cellulose 10 Flour 5 Calcium silicate 30 T CM T B 1 Busan 11” 2 Water until it reaches 100 Takumi Dan Modified acrylic HF208 (ICI) 25 Magnesium phosphate 30 TT 615 2 Borax 2 Busan 1009 1 Water until it reaches 100 υ Polymer Lowplex WLQ6 25 Magnesium chloride 30 Q　R7082 Busan I+”2 Busan 1009 1 Water until it reaches 100

Claims (26)

[Claims] 1. Provide shredded cellulose fibrous material and apply a hard or non-hard binder to the shredded material. coating to form a coated shredded material, the non-fibrillarized cellulose material being coated Introducing onto and into the shredded material to provide a filled shredded material, and compressing the filled shredded material. pressing and curing to bond the materials with the binder to form a cellulose fiber insulation material; A method for producing an open cellulose fiber insulation material, comprising: 2. Card or comb the shredded material before applying the binder to defibrillate the material. A method according to claim 1 which provides a loosely uniformly formed layer of material which facilitates the introduction of the material. Law. 3. A claim in which a binder is further applied to the filled shredded material before squeezing and curing. The method described in 1 or 2. 4. Fill the shredded material with a card or comb before applying further binder to ensure non-fiber A lurified material is distributed in the shredded material and an additional binder is distributed in the filled shredded material. 4. The method according to claim 3, which facilitates penetration. 5. The method of claim 1, wherein the binder comprises a thermosetting plastic material. 6. Claims that the binder additionally contains one or more phosphorus refractors and/or biocides The method described in Section 5. 7. Biocide selected from fungicides, bactericides, insecticides and/or rodenticides 7. The method according to claim 6. 8. The binder is applied as a coating to the shredded cellulose material by sprayer(s). 2. The method according to claim 1, wherein the method is applied. 9. Claim further that the binder is applied to the filled shredded material by sprayer(s) The method described in Section 3. 10. 2. The method of claim 1, wherein the cellulose fiber insulation material is cut into strips or batts. . 11. Claims that the thermosetting plastic material is a flexible thermosetting plastic material The method described in Section 5. 12. means for forming a uniformly distributed mat of shredded cellulose material; Means of introducing non-fibrillarized cellulose material into ululose material, each surface of the mat means for providing a covering sheet of cellulosic material on a surface, said shredded cellulose material and said The shredded cellulose and Apparatus for producing cellulose insulation material comprising means for introducing a binder into the covering sheet . 13. 13. The apparatus of claim 12, comprising a shredder for providing shredded cellulosic material. 14. Spread the shredded cellulose material to create a mat of evenly distributed cellulose material. Claims formed by a bed of chain conveyor mechanism spreading out from the shredder for uniform distribution. 13. The device according to 12. 15. A chain conveyor mechanism spreads and evenly distributes the shredded cellulose material. 15. The device according to claim 14, having spikes directed toward the direction. 16. Claim 15: The conveyor mechanism also serves to transport shredded cellulose material. The device described in. 17. Claims comprising one or more atomizers for introducing the binder into the shredded cellulose material 13. The device according to 12. 18. A means of introducing non-fibrillated cellulosic material is provided across the width of the shredded material. Mechanism for uniformly distributing non-fibrillated cellulose material and said non-fibrillated cellulose material a compressed air mechanism for forcing cellulosic material into and onto the shredded cellulosic material; 13. The device according to claim 12. 19. 13. The apparatus of claim 12, further comprising means for curing the bonded insulating material. 20. Hands for transporting and forcing shredded cellulose material from the conveyor mechanism to the curing means 13. The device of claim 12, comprising steps. 21. Shredded cellulose material with non-fibrillarized cellulose material present in and on top material, and said insulating material in the form of a web, strip, roll, blanket, or batt. An open cellulose fiber insulation material consisting of a bonding agent. 22. 22. The insulation of claim 21, wherein the binder comprises a flexible thermoset plastic material. material. 23. The binder contains one or more flame retardants and/or fungicides, bactericides, 22. The insulating material of claim 21, further comprising a biocide such as an insecticide and/or rodenticide. . 24. 22. The insulating material of claim 21, wherein the binder further comprises filler(s). 25. Flame retardant treated paper on both sides of the web, strip, roll, blanket or batt. The insulating material according to claim 21, comprising a cover sheet. 26. Non-fibrillarized cellulose material is non-fibrillarized cellulose material treated with flame retardant. 22. The insulating material according to claim 21, which is a base material.