JPS6179603A - Manufacture of mineral fiber board - 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 (Field of Industrial Application) The present invention relates to a method for producing mineral fiberboard used as ceiling materials and wall materials of buildings, or as panel materials for ponds.

(Structure of conventional example and its problems) Traditionally, in order to manufacture mineral fiberboards such as rock wool and slag wool used for ceiling materials, it has been necessary to obtain the desired thermal insulation properties,
For the purpose of reducing weight or improving productivity, 4 to 30
It is mainly composed of mineral fibers with a relatively long fiber length, and is wet-formed with a low slurry concentration. However, unlike organic fibers such as wood pulp, mineral fibers lack flexibility ( Therefore, the surface of the cloak obtained by paper-making mainly from long fibers becomes noticeably uneven, and the surface smoothness is reduced to 18. After drying the mat, surface treatment by sanding is required.

In addition, mineral WLl whose surface was smoothed by sanding
Even with I-Ikari, since the surface is porous, the paint is absorbed during painting, resulting in poor paintability.It is necessary to apply an undercoat to reduce the variation in absorption before finishing the painting, which reduces productivity, etc. There was a problem.

(Object of the Invention) The present invention has been made in view of the above-mentioned conventional problems, and is aimed at manufacturing mineral fiberboard with the aim of eliminating the need for sanding treatment and improving surface cosmetic properties such as paintability. The present invention provides a method.

(Structure of the Invention) In order to achieve the above-mentioned object, the present invention provides a method for applying mineral short fibers having an average tdJi fiber length of 100 to 2000μ on the surface of a wet mat obtained by paper-making a slurry mainly composed of mineral fibers. A step of providing a mineral short fiber layer by supplying a slurry mainly composed of This is a manufacturing method for mineral fiberboard, which consists of a step of pressing a layer of short mineral fibers, and a step of drying after pressing. Entanglement can be easily and reliably obtained, a smooth and highly superior surface layer can be formed by the mineral short fiber layer, and mineral fiberboard can be manufactured efficiently.

(Explanation of Embodiments) Embodiments of the present invention will be described with reference to the drawings. The main fibers are mineral fibers with a fiber length of 4 to 3 degrees, such as rock wool and slag wool, and pearlite and shirasu foamed fibers are used as needed. A slurry is prepared by mixing inorganic foamed lightweight aggregates such as carbon fiber, waste paper pulp, etc., and further adding an appropriate amount of a binder such as starch, and is made into paper using a Marujun papermaking machine or a Fourdrinier papermaking machine, so that the specific gravity after drying is 0. A wet mat (1) with a low density of 2 to 0.3 is formed.

On the other hand, mineral fibers such as rock wool and slag wool are pulverized into short fibers with a fiber length of 1,00 to 2,000μ, preferably 100 to 1,000μ. A binder such as starch, PVA, phenol, acrylic, acrylic styrene, or petroleum resin is added in a proportion of , clay, warping force, magosium carbonate, mineral powder, mica 1″A, metal powder, aluminum hydroxide,
Appropriate amounts of inorganic powder such as alumina powder, carbon black, and white carbon are added to form a slurry mainly consisting of mineral short fibers, and this slurry is used as the wet mat IL).
A high-density short mineral fiber layer (with a dry specific gravity of 0.3 to 0.5) that is thinner than the wet mat (1) is supplied to the surface of the wet mat (1).
2) will be provided.

At this time, the concentration of the slurry mainly composed of mineral short fibers is adjusted to a high concentration of S in order to minimize the decrease in the strength of the wet mat, and the supply to the surface of Wetmano 1 is a certain amount. Do this continuously at the same rate so that the thickness is approximately uniform.

In addition, since the binder and colorant are mixed into the slurry and supplied to the wet mat surface along with the mineral short fibers, their fixation and yield can be completely achieved, making it possible to avoid problems that are difficult to form or fix. Since there is no need to separately form and laminate the surface layer, short fibers with poor drainage properties and fine powders can be layered and integrated with high productivity.

Next, the laminated mat with the mineral short fiber layer provided on the surface of the wet mat is dehydrated. This dehydration may be carried out by natural dehydration using the water's own weight by running the regular feeding line after papermaking, but it is also possible to perform dehydration under pressure using upper and lower press rolls (31 (41) or a flat plate press, or by using a wet mantle). If the dehydration is carried out by suction (5) from the bottom side of (1) or by both pressurization and vacuum dehydration, the wet mat (11) and the mineral short fiber layer (2) will be in close contact with each other. This is preferable because the dehydration efficiency can be further improved.

After dehydrating the laminated mat and before drying, press the top surface of the mineral short fiber layer on the surface of the mat with a roll press or flat plate press. In this case, an appropriate uneven pattern is engraved on the roll or flat plate press. Then, an uneven pattern may be imprinted on the mineral staple fiber layer at the same time as pressing.

Note that this pressing densifies the surface of the mineral short fiber layer to make it highly hard, and also increases the adhesion between the wet mat and the mineral short fiber layer to prevent peeling between the eyebrows.

Furthermore, by performing the above-mentioned pressing while the binder such as starch is not yet hardened and undried, the destruction of the mineral fibers constituting the wet mat is reduced and the surface is densified without reducing the strength. It is something. Such surface pressing treatment may be performed either after or before dehydration of the laminated mat, but as mentioned above, if performed after dehydration, short mineral fibers may adhere to the pressing device of the roll or press plate. This is preferable because it can improve the smoothness and make the pattern more visible.

Next, the laminated pine 1 is dried by an appropriate drying means, and as shown in FIG. 3, the upper layer is a dense and highly hard mineral short fiber layer (2) mainly composed of mineral short fibers,
A fiberboard (Δ) is obtained in which the lower layer is a low-density mineral fiber layer (11) formed of mineral TA fibers having a relatively long fiber length.

In the above manufacturing method, before supplying the slurry mainly composed of mineral short fibers onto the wet mantle (1), starch, phenol, etc.
A binder such as melamine may be sprayed to improve adhesion at the interface with the slurry. In this case, it is preferable not to use a powdered binder to prevent fluidity due to movement of water in the slurry.

In addition, when using a liquid binder, wet mat (1)
After a mineral short fiber layer (2) is provided on the surface of the mineral short fiber layer, it may be applied to the surface of this short fiber layer.

According to this method of surface application of a liquid binder, the liquid binder is applied to the mineral short fiber layer 12 and the wet pine I-(1
Penetrates to the interface of 1, increases the adhesion between layers, and prevents delamination of 1.
41t can be prevented, and at the same time, the surface hardness can be increased by the binder that has penetrated into the short fiber layer 12.

In addition, after applying the binder before dehydration, if the wet mat is suctioned from the bottom side of the wet mat or dehydrated under pressure, some of the liquid binder will be absorbed into the inside of the wet mat as the water moves. It can also be infiltrated.

Application of such a binder is not necessarily necessary, since if a large amount of binder is added to the slurry, the binder can be used to increase the bonding strength between the eyebrows.

(Effects of the Invention) As described above, according to the method for manufacturing a mineral fiberboard of the present invention, the surface of the wet mat obtained by paper-making a slurry mainly composed of mineral fibers has an average fiber length of 100 to 200
A slurry mainly composed of 0μ mineral short fibers is supplied to form 1mm mineral short fibers, which are dehydrated in this state, pressed, and then dried. Therefore, the mineral short fibers are made into a wet mat in a slurry state. Since the short mineral fibers are supplied to the surface, the short mineral fibers flow into the underlying mineral fiber layer with the movement of water, strengthening the bond between the two layers and creating a mat of the short mineral fibers in a slurry state. Since the paper is supplied directly to the surface, there is no drop in the papermaking speed of the wet mat (and production efficiency can be improved. Moreover, by dehydrating both in a layered state, the adhesion of the fibers between the eyebrows to each other is even better. This makes it difficult for the surface layer to peel off (and even if the surface of the wet cloak is porous and highly uneven, it can be layered evenly).

Furthermore, by dehydrating both in a laminated state, the movement of water during dehydration promotes the transfer of binder and the entanglement of fibers between the surface mineral short fiber layer and the lower mineral fiber layer, making both strong. In particular, if suction dehydration is used, the intertwining and bonding parts of the glabellar fibers will not be destroyed, and the weight can be reduced by eliminating the increase in the specific gravity of the lower layer Wetmano1-. At the same time, it is possible to create irregularities on the surface, and also to harden the surface layer without destroying the underlying layer.

In addition, since the surface layer is made of short mineral fibers, it is not only highly waterproof, but also has a dense and flat surface.
It eliminates the need for surface conditioning treatments such as sanding, and because the surface is dense and dense, it absorbs less paint, eliminates the need for an undercoat, and can form a good paint film with a small amount of paint. Also, since there is little absorption in the application of the adhesive, it is possible to easily and reliably adhere the surface decorative sheet.

Furthermore, since the surface layer is dense and dense, it is hard and has excellent compression resistance, impact resistance, and bending strength, and the mineral short fiber layer that makes up the surface layer is made of phenolic resin that has excellent water resistance. When formed with the addition of a binder, absorption from the surface is suppressed, there is little loss of strength due to moisture absorption, and it is possible to obtain a mineral fiberboard with excellent moisture resistance.

4. Nodes of 121 planes
Figure 2 is a simplified side view of essential parts showing an embodiment of another dehydration method, and Figure 3 is a sectional view showing a fiberboard processed by the method of the present invention.

(1)...Wet mat, (2)...Mineral short fiber layer, (:11 (4)...Press roll, (5)...
・Suction dehydration.

Patent applicant: Daiken Kogyo Co., Ltd.

Claims (3)

[Claims] (1) On the surface of a wet mat obtained by paper-making a slurry mainly composed of mineral fibers, an average fiber length of 100 to 2
A step of supplying a slurry mainly composed of 000μ mineral short fibers to form a mineral short fiber layer, a step of dehydrating the wet mat and the mineral short fiber layer in a laminated state, and pressing the mineral short fiber layer. 1. A method for producing a mineral fiberboard, comprising: a step of pressing, and a step of drying after pressing. (2) When supplying the slurry mainly composed of short mineral fibers to the surface of the wet mat, the slurry is supplied after previously sprinkling a binder on the surface of the wet mat. A method for producing a mineral fiberboard as described in Section 1. (3) After providing the mineral short fiber layer on the wet mat surface and before drying, a binder solution is sprayed on the surface of the mineral short fiber layer. Method for manufacturing mineral fiberboard.