JPS58138632A - Method for continuously molding decorative corrugated article from flame-retardant glass wool - Google Patents

Abstract

PURPOSE:To uniformly adhere a decorative material, by a method wherein a sheet form fibrous material and a flame-retardant hot-melting type polymer film having a melting point of not lower than 120 deg.C are laminated on each other, and the resultant laminate body is fed onto the upper surface of a glass wool mat to be molded. CONSTITUTION:An aggregated mat 13 with a binder such as a phenolic resin uniformly contained therein is continuously fed to a corrugating molding device, and immediately before the mat 13 reaches an inlet to sheet form belts 3, 4, a rolled form flame-retardant polymer (e.g., polyethylene) film 8 for adhesive purpose and the fibrous material 7 to be a surface decorative material which are rotatably supported by shafts on upper parts are fed onto the surface of the mat 13 through a stretching roll 9. Accordingly, at the time of corrugation molding, a slipping is easily brought about on the polymer film 8 concurrently with the corrugation of the glass wool, and a decorative corrugated glass wool molded article with one side uniformly covered by fibers can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a corrugated glass wool molded article, in which a fibrous decorative material is attached to cover one side of a corrugated glass wool molded article. More specifically, the present invention relates to a method of attaching fibers from a glass wool mat (used as a decorative material during wave molding) to one side of the molded product.

Corrugated glass wool is made by impregnating short glass fibers with a small amount of a binder and collecting the mat.

This corrugated molded product is used as a slate heat-insulating and sound-absorbing material by adhering one side to a corrugated slate.

A normal molded product that does not cover the surface of a corrugated glass wool molded product is called a bare product, and if it is directly attached to a slate and used as a heat-insulating and sound-absorbing material, the shot of the glass will be in your hand during construction. There were drawbacks such as punctures, damage to the glass wool molding on one side of the bonded slates, and fuzzing.

In addition, the binder used to form the glass school is usually a highly flame-retardant phenolic resin aqueous solution, but due to uneven impregnation of the resin liquid and uneven firing temperature during molding, significant yellow coloring can occur during molding. 4. On both sides of the object. ; If used as is for interior materials such as wall materials, the aesthetic appearance will be significantly impaired and the commercial value of slate as a flame-retardant and sound-absorbing material will decrease.

In order to solve the above-mentioned drawbacks, the present applicant targeted corrugated glass wool for slate and applied thin sheet-like fibers such as nonwoven fabric or cheesecloth to only one side of the corrugated glass wool molding that is not bonded to the slate. However, if a breathable fibrous decorative material such as non-woven fabric or cheesecloth is attached to one side of the corrugated material and this is attached to slate, the sound absorption properties of the glass coat will not be affected, but flammable fibers such as non-woven fabric or cheesecloth will Unless flame-retardant treated fibers are used as a decorative material, the fire-retardant performance of the insulation and sound-absorbing slate material will be poor. In addition, when attaching decorative materials such as fibers to a corrugated glass wool molded product as a surface covering material, it is difficult to apply uniformly after molding because the molded material to be covered is corrugated, and glass wool When molding into a corrugated Km shape, sheet fibers are sandwiched onto the mat to be molded, and the same molding process is performed.

Sometimes, even if fibers are pasted, not only will it not be possible to obtain a corrugated molded product with a uniform wave width and thickness, but also the fibers and the mat to be formed will be folded to the sides, making one side of the molded product uniform in the form of a sheet. It was found that it was not possible to obtain a decorative wave-type molded product covered with fibers.

Wave-shaped glass wool moldings for slate, which are usually called bare materials, are obtained by forming collected mats of glass wool impregnated with a binder into a wave shape. Since the width is reduced in the process of corrugating (normally in the case of large wave slate products, the width is reduced by 1.2 at the knee compared to the width when flat), in the forming method using a normal caterpillar corrugated plate, the upper and lower The object to be formed is placed between two heat-resistant endless belts facing each other, adjusted to be slightly wider than the width of the inlet of the caterpillar conveyor, and continuously introduced into the caterpillar conveyor, where the width of 200~ A caterpillar consisting of corrugated templates that are driven vertically and facing each other in a heating furnace at 2'50°C! Compression molded using a heat-resistant endless belt using a mold plate.

In this conventional method, during 4-t O-wave compression molding, the endless belt is introduced into the caterpillar conveyor under tension in the traveling direction, and is also sandwiched between the corrugated plates via the heat-resistant endless belt. If the mat is immediately formed from a flat plate shape to a corrugated shape without forming corrugation wrinkles in advance, it will not be possible to smoothly reduce the mat in the lateral direction to form the corrugated shape, and the mat will not be introduced into the caterpillar conveyor. The moment the mat is bitten into the corrugated board, the mat is pulled in the width direction and may be torn at the template centering around the middle of the mat, or the thickness and wave width may not be constant.
≦4. Therefore, a uniform molded product cannot be obtained.

To solve this problem, when the endless belt is sandwiched between the belts before being subjected to corrugation, the central part of the belt should be corrugated (wrinkled) more deeply in advance, and the ends of the belt should be corrugated (wrinkled) more deeply. The applicant also proposed a continuous forming device in which a plurality of smaller rollers were installed in front of a caterpillar run conveyor. (I!# Kimiaki-52-2
5452) Using the above-mentioned Japanese Patent Publication No. 52-25432 device,
If the upper and lower endless belts holding the glass wool mat to be formed are corrugated in advance, the center part of the upper and lower endless belts is deep, and the corrugations are made symmetrically to the left and right and gradually become shallower to both ends. Before the object to be formed is introduced into the caterpillar conveyor, the width direction is reduced by corrugation to match the width of the inlet of the caterpillar conveyor, and the object is moved while being pulled in the subordinate direction. The corrugation moves sequentially to both the left and right ends and is brought to the L side.

As a result, when it is introduced into the caterpillar, the entire belt and the clamped workpiece fit into the liquid of the corrugated plate of the caterpillar, and there are no partial wrinkles or uneven thickness caused by corrugation. Since the molded product is shaped in a free-form state, it is possible to obtain a uniform wave-shaped molded product without being torn by the instant template introduced into the belt conveyor.

However, even if this device is used to mold so-called bare corrugated glass wool, insert sheet-like fibers that will serve as a decorative material and paste them during molding, unless the glue used for pasting is specified, it will not work normally. il” with molded lid
As with the previous case, it was found that uniform pasting was not possible. The method of the present invention was proposed to solve this problem.

That is, in the present invention, prior to corrugating a glass wool mat impregnated with a binder using vertically opposing endless corrugated plate caterpillar conveyors, the mat to be formed is inserted between the endless belts above and below the mat to be formed in advance. The center part of the belt is large to form corrugated wrinkles on the mat and endless belt.
Using a corrugating device in which a plurality of corrugated wrinkle rollers with small roller diameters are installed in front of a caterpillar conveyor at the ends, fibers are coated on one side of the molded product at the same time as the mat to be formed is corrugated. This method is characterized by using a flame-retardant hot-melt poly film with a melting temperature of 120° C. or higher or laminating the poly film on the back side of the fiber as a filter paste used for pasting.

As mentioned above, the apparatus used in the method of the present invention is an apparatus equipped with a plurality of rollers of different diameters for pre-corrugating before corrugation, and a detailed description of the apparatus is not particularly provided. Since it is described in Publication No. 52-25452, it will be omitted here. 1 In the method of the present invention, sheet fibers that serve as decorative materials or sheet fibers whose back side is laminated with hot-melt polyfilm are "sandwiched between endless belts before being corrugated with cola. The corrugated material is placed on a glass wool mat that is moved by an endless belt, and is introduced into rollers while being sandwiched by an endless belt.

The adhesive used to attach the fibers is a flame-retardant hot-melt Quino poly film with a melting temperature of 120°C or higher, and when using fibers that are not laminated, the poly film has the same speed as that of the laminated state. And I'm caught in the middle. In the method of the present invention, it is necessary to use a hot-melt polyfilm as the glue, and before introducing it into the endless belt, an adhesive solution that becomes the glue is coated or sprayed to sandwich the decorative fibers. In this case, the fiber sheet that is then applied with pressure by the corrugating (wrinkling) roller is either locally stuck to the top of the mat and temporarily glued, or it is difficult to move freely on the top of the mat. Become. As described above, the endless belt whose central part is deeply corrugated by corrugation and the workpieces held therebetween are wrinkled at both left and right ends during the movement until they are introduced into the caterpillar conveyor. At the moment when it is introduced into the conveyor template, the glass wool mat is like a corrugated caterpillar plate.

The mat must be shaped so that it matches the width and also roughly matches the width of the fibers of the corrugated decorative material. If the fibers cannot move freely, they are led to the caterpillar conveyor in a folded state. In addition, at the moment when the workpiece is bitten into the corrugated plate of the caterpillar conveyor, the length of the semicircular recesses and convexities of the corrugated workpiece differs depending on the mat thickness. The fibers held by the endless belt in the section need to move slightly smoothly from side to side in the width direction at the same time as they are held by the template, but this is not possible.

The method of the present invention uses a smooth and slippery poly film between the fibers and the mat, and since the fibers are only placed on the mat, the glass wool mat can separate from the fibers and move freely as it is molded. This enables uniform application without wrinkles. Furthermore, using the above-mentioned Japanese Patent Publication No. 52-25432 equipment, the central part of the heat-resistant endless belt was corrugated slightly deeper than when molding the bare corrugated glass loop (thereby, the heat-resistant endless belt...
When introducing the heat-resistant endless belt into a template, it is also possible to insert the heat-resistant endless belt into a template with the center part slightly ahead of both ends, thereby achieving even greater effectiveness.

This can be easily achieved by appropriately adjusting the diameters of the plurality of corrugated rollers.

FIG. 1 is a diagram illustrating an apparatus for explaining an embodiment of the method of the present invention for producing a corrugated glass wool molded article whose one side is covered with decorative fibers when unlaminated fibers are used. .

The method of the present invention will be explained with reference to FIG.

In Fig. 1, 1.2 is an upper and lower corrugated endless plate caterpillar conveyor, 6.4 is an endless heat-resistant sheet-like belt made of polyfluoroethylene fiber, 1-fiber, etc. Wave is a roll device, 7 is a sheet-like fiber that is a surface decorative material made by rolling non-woven fabric or cheesecloth, 8 is a soft melt type poly film roll roll for adhesion with flame retardancy, 9
10 is the width cutter, 11 is the feed wrinkle smoothing roller, and 10 is the width cutter.
is a length cutter. The collected pine 13 uniformly containing a binder such as phenolic resin is continuously supplied to the corrugation forming device, and is freely placed on the top/part of the sheet belt just before reaching the entrance K of the sheet belt in 3.4. A p-outer-wound adhesive flame-retardant poly film 8 held by a shaft so as to be rotatable and a fiber 7 serving as a surface decorative material are moved to a wrinkle-smoothing roller 9
is fed onto the glass wool mat surface through. The hot-melt polyfil type is preferably a polyone fin film such as polyethylene or polypropylene.
It is a flame-retardant polyfilm having a thickness of 10 to 100 μm, preferably about 20 to 50 μm, and a melting point of 120° C. or higher. It is easily available.Also, as shown in Fig. 2, the wrinkle smoothing roller 9 for feeding poly film and decorative material spreads the decorative material and poly film to the left and right when it is rotated in contact with the decorative material and poly film. This is a rotating shaft that has spiral grooves from the center to the left and right.With this, the decorative material fibers and sheet-like polyfilm are spread left and right and stacked on top of each other, and the glass wool is sandwiched at the same speed by the endless belt 3.4. The tension and speed of the decorative fibers and the poly film layered underneath them at the same speed are controlled by the rotary motor driving the endless belt 4 and caterpillar conveyor. The roll of decorative material and poly film is adjusted according to the speed by applying a brake on the shaft. The decorative fiber sheet and poly film stretched at high speed are sandwiched between heat-resistant endless belts and introduced into the corrugating p-ra 5.6, where they are corrugated from above and below together with the cloak.

The diameter of the rollers 5 and 6 is large at the center and becomes smaller toward both ends, and the mat made of the decorative material and polyfilm is corrugated more deeply near the center of the heat-resistant endless belt. Ru. Cold air is blown into the area around the corrugated roller, and the temperature of the TI-RA is kept below 100°C. The corrugated mud to be formed is introduced into a heating device 12K and is formed into a corrugated shape via a belt 6.4 between an upper and lower corrugated endless template caterpillar conveyor 1.2 heated to 200 to 250°C, and then transferred to a cutter 10. .11 Cut to a more appropriate width and length.

In Tonoyo 5, the decorative fiber sheet is sandwiched between the heat-resistant endless belt and stretched while passing through the wrinkle-removal roller, and the corrugation is introduced in front of the roller and in front of the heat-resistant endless belt. Since Fiber Sheet F is simply layered on top of a smooth poly film, it can easily slide and move on the poly film as the glass wool wrinkles during wave forming, allowing one side to be uniformly covered with fibers. A covered decorative corrugated glass wool molding can be obtained.

The molded product obtained by the method of the present invention not only has one side neatly covered with the fibers of the decorative material, but also the nonwoven fabric, cheesecloth, etc. that can be used as the decorative material are available at low cost. If you can use it to match your favorite color, it can also be used as a colorful interior material.

be. In addition, the fibers covered on one side of the molded product are combined with the hot-melt flame-retardant polymer used for adhesion, and even when used as a heat insulating material for slate, it has almost the same fire protection as a bare molded product. It has performance. Further, a manufacturing method that meets the flame retardant test standards for building interior materials is also possible, and can be easily formed by the method of the present invention by appropriately selecting the thickness of the flame retardant polyfilm.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of a diagrammatically illustrated apparatus for carrying out one embodiment of the method of the invention. 1.2 is a caterpillar conveyor connected by corrugated plates 6.4 is a heat-resistant endless belt 7 is 1...2 rolls of sheet-like fiber 8 is a roll-wound hot mesh C'''T-shaped flame-retardant polyethylene 9 is Wrinkle removing roller Figure 2 is an enlarged view of the wrinkle removing roller 9 shown in Figure 1.To the patent applicant Mitsui Toatsu Chemical Co., Ltd. y Early 1 Figure 2 Procedure Amendment 嘗 (Method) % Formula % l Incident Indication 1982 Patent Application No. 19701 Title of Invention Continuous Molding Method for Flame Retardant Cosmetic Corrugated Glass Wool Moldings 3rd Amendment Contents of Supplementary Drawing 6 iE

Claims (1)

[Claims] 1. A method in which a glass wool mat to be formed impregnated with a binder is formed into a corrugated shape using an endless corrugated molded conveyor conveyor facing vertically, and at the same time a fibrous decorative material is attached to one side of the corrugated molded material. In order to form corrugation wrinkles in advance on the mat to be formed, the mat to be formed is sandwiched between vertically opposing endless belts, with large wrinkles at the center of the belt and wrinkles at the ends of the belt. Using a corrugating device installed in front of a caterpillar conveyor with a plurality of wrinkled rollers having a small roller diameter, sheet fibers and flame-retardant hot-melt polyfil having a melting temperature of 120°C or higher are produced. Continuous molding method 2 for flame-retardant decorative corrugated glass wool moldings, in which one side of the molded product is covered with fibers at the same time as corrugation, by stacking a person on top of the glass wool mat to be molded, and applying a binder. In this method, an impregnated glass wool mat to be formed is formed into a corrugated shape using an endless corrugated plate caterpillar conveyor that faces each other vertically, and at the same time a fibrous decorative material is attached to one side of the corrugated material. Prior to corrugation, in order to form corrugation wrinkles in advance, the mat to be wrinkled is sandwiched between vertically opposing endless belts, and a p-ra is used, which is large at the center of the belt and small at the ends of the belt. A sheet-like fiber laminated with a flame-retardant hot-melt potion filler having a melting temperature of 120°C or higher using a wave-forming device installed in front of a caterpillar conveyor. A continuous molding method for a flame-retardant decorative corrugated glass wool molded product, which is introduced onto the upper surface of the glass wool mat to be molded and simultaneously covers one side of the molded product with fibers.