JPS6233853A - Method and apparatus for producing inorganic fiber mat - 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 [Industrial Field of Application] The present invention relates to a method and apparatus for producing an inorganic fiber mat that can produce an inorganic fiber mat with excellent thickness recovery ability.

[Prior Art] Inorganic ta fiber mats such as glass wool, rock wool, and slag wool are widely used as heat insulating materials, sound absorbing materials, and the like. To produce such an inorganic TAM mat, heat-softening inorganic substances such as glass, rock, and slag are made into short fibers by methods such as steam blowing, flame stretching, centrifugation, and RGJ. A fiber forming unit is made to fly, and a binder such as an aqueous solution of phenol resin is sprayed onto the fibers in flight, which is then collected by a cotton collecting conveyor installed below the fiber forming unit, commonly known as green mat. It is made into a wire state with an uncured resin binder.

Then, the cotton collection conveyor is moved, and the raw mat on it is introduced into a heat treatment furnace (oven), and the thickness of the mat is adjusted to a predetermined thickness while the binder component is cured. In this heat treatment furnace, hot air with a controlled temperature is passed between the mats to evaporate the water in the resin, further harden the resin, bond the fibers together, and create a mat-like product with a constant thickness. After leaving the heat treatment furnace, the product is cut into desired dimensions.

Note that the above-mentioned steam blowing method is a method in which high-pressure steam is sprayed onto the flowing molten inorganic material to blow it out and make it into a thin wire.

The flame stretching method is a method in which an inorganic substance is drawn out as a thin linear body, and then a high-speed flame is applied to it to refine it.

The centrifugal method is a method in which molten inorganic substances are shaken off by centrifugal force, and then pulverized by applying high-speed airflow.

The RGJ method is a rotary gas jet method that has become known in recent years, and is a method in which high-temperature, high-pressure gas is sprayed in a spiral along the flow of a molten inorganic material to make it fine.

Therefore, when shipping the inorganic fiber mat produced as described above, in order to reduce the volume of the raw mat to reduce the transportation space and transportation cost, it is necessary to reduce the volume of the raw mat to, for example, 1/3 of the original volume. For example, in the case of a low-density glass fiber mat with a density of 8 to 16 kg/m', the nominal thickness is It is compressed and packed until it is reduced to about 10%.

[Problems to be Solved by the Invention] An unpacked inorganic fiber mat recovers its thickness due to its own elasticity and exhibits a certain heat insulating property or sound absorbing property. If the size is increased, a thicker mat can be obtained after unpacking, which is advantageous.

However, inorganic fiber mats manufactured by conventional manufacturing methods and devices do not necessarily have sufficient restoring ability.

[Means for Solving the Problems] The method for producing an inorganic fiber mat of the present invention involves spraying a binder onto the fibers of an inorganic heat-softening substance that have been thinned by an H&fiber means, and collecting the fibers on a cotton collection conveyor. When producing an inorganic fiber mat by introducing the raw mat into a heat treatment furnace, air is introduced into the raw mat introduced into the heat treatment furnace in advance to increase the thickness of the raw mat. I decided to keep it.

Further, the inorganic fiber mat manufacturing apparatus of the present invention includes a fiberizing means for fiberizing a heat-softening substance, and a fiberizing means for fiberizing a heat-softening substance. a fiber fiber means; a spray nozzle for spraying a binder onto the fibers of the heat-softening material that has been made into fibers; a cotton collecting box for collecting the fibers onto which the binder has been sprayed; and a cotton collecting box at the bottom of the cotton collecting box. In an apparatus for producing an inorganic fiber mat, which has a cotton collecting conveyor and a suction provided on the opposite side of the cotton collecting conveyor from the cotton collecting case, air is drawn into the raw mat coming out of the cotton collecting case. A jetting means or a suction means is provided for introducing the water.

[Function] In the present invention, air is introduced into the raw mat before it is introduced into the heat treatment furnace to increase its thickness, and then the raw mat is introduced into the heat treatment furnace and heat treated.

Therefore, a thick (low density) inorganic fiber mat is taken out of the heat treatment furnace. Therefore.

If this is compressed to the same volume as before, even after unpacking, it will recover to a larger thickness than before.

As described above, according to the present invention, it is possible to manufacture an inorganic fiber mat with a high thickness recovery ability.

[Example] Examples will be described below with reference to the drawings.

FIG. 1 is a longitudinal cross-sectional view of an apparatus for producing an inorganic fiber mat according to an embodiment of the present invention.

The glass fabric 12 melted in the glass melting furnace 10 is subjected to temperature control in the foreground 14 . Then, the flow rate is controlled by the plunger 1 from the spout 16 at the bottom.
8, the fibers flow down to a fiberizing means 20 using the so-called rotary gas jet method disclosed in Japanese Patent Application Laid-Open No. 52-25113, and are thinned into fibers 22.

A binder 26 such as a phenolic resin aqueous solution is sprayed from a spray nozzle 24 provided below the fiberizing means 20.
It is sprayed toward the fibers that have been thinned by the fiberizing means 20.

A cotton collecting box 28 is provided below each fiberizing means 20, and the fibers 22 that have been made into fibers by the fiber hand means 20 and have been sprayed with binder from the spray nozzle 24 are stored in this cotton collecting box 28. The cotton falls and is deposited on the cotton collection conveyor 30 installed at the bottom of the cotton collection box 28. Cotton collection conveyor 30
A suction #J32 is installed below the suction #J32, and the pressure inside this suction #J32 is reduced by a suction blower (not shown), and the high-temperature gas ejected from the fiberization means 20 for fiberization is The fibers pass through the cotton collection canister 28 together with the surrounding outside air, pass through the accumulated fibers and the cotton collection conveyor 30, and are sucked into the suction canister 32.

The fibers 22 collected on the cotton collection conveyor 30 are moved to the right in the figure, and the thickness of the pile gradually increases, and the fibers 22 are collected as a raw mat 34! Exit 112B. This raw mat 34 is made thicker by introducing air into it midway through, and is then introduced into a heat treatment furnace (oven) 38 via a leading conveyor 36, where it undergoes treatment to evaporate the water in the binder and heat harden it. The resin component is cured,
It is molded as an inorganic fiber mat of a predetermined thickness.

In the apparatus of the present invention, an air suction means or air jetting means is used to introduce air into the green mat 34. Next, the structure of this air jetting means or suction means will be explained.

In the embodiment shown in FIG. 1, a body 40 is installed opposite the lower surface of the conveying surface of the cotton collection conveyor 30 coming out of the cotton collection container 28, and a spout 42 is opened on the upper surface of this body 40. ing.

2 and 3 are an enlarged cross-sectional view and a perspective view showing the configuration of this body 40. As shown in FIG. 0, a blower 45 is connected to the body 40 through an air introduction pipe 44, A damper 46 for the amount of introduced air FAWI is installed at 44. In this embodiment, the openings 42 are circular openings arranged in a staggered manner as shown in FIG. The thickness of the green mat 34 can be efficiently increased by blowing out air and introducing most of the blown air into the green mat 34. As a result of various experiments, it has been found that it is most efficient to arrange the openings in a staggered arrangement as shown in the figure.

Note that the opening 42 does not have to be circular, and may be a rectangular opening such as a quadrangle or a pentagon.

The opening provided on the upper surface of the housing 40 may be a slit-shaped opening 50 extending in the moving direction of the cotton collection conveyor 30, as shown in FIG.

Note that when air is introduced into the raw mat 34 from the lower surface side of the raw mat 34 as in this embodiment, the air is introduced uniformly into the raw mat 34 and is ejected from the air jetting means such as the cover body 40. In order to efficiently produce a mat of uniform thickness, it is important to configure the mat so that most of the air is introduced into the green mat. Therefore, for example, a case in which a slit is provided extending in a direction perpendicular to the raw mat conveying direction prevents the air ejected from both ends of the slit from entering the raw pine and the sides of the raw mat. Since there is a strong tendency for the punch to come out from the part, the device of the present invention does not provide a very good thickness increasing effect.

In the present invention, any device that can increase the thickness of the raw mat by introducing air into the raw mat can be used. For example, as shown in FIG. A suction box 52 may be installed and air may be sucked through the lower opening 54 of the suction box 52. In this case, air is introduced into the raw mat 34 so that the upper surface of the raw mat 34 is blown up, thereby increasing the thickness of the raw mat 34.

It is also possible to install both a device that blows out air from the bottom of the raw mat as shown in Figures 1 to 4, and a device that sucks air from the top of the raw mat as shown in Figure 5. good.

In the apparatus of the present invention, by using low-humidity air as the air introduced into the green mat, it is possible to produce an inorganic fiber mat with even better restoring ability.

That is, cotton collection I! The inside of the Pf 128 is filled with water vapor that evaporates from the binder liquid that is sprayed in the form of an aqueous solution over 9 m22, and high-temperature gas for fineness is being ejected into the Pf 128. The inside of the cotton collection box 28 is hot and humid, and the air layer inside the fiber cotton collected on the cotton collection conveyor 30 is also hot and humid. In this state, collect cotton! Heat treatment furnace 3B to the outside of 1l128
When the raw mat 34 is sent out toward
Since the raw mat 34 is at room temperature), the air inside the raw mat 34 is cooled, causing dew condensation, and moisture adheres to the fibers. Then, this moisture dissolves the resin that had previously adhered, forming large resin particles. The larger the resin particles become, when they are cured in the oven, only the surface layer is cured first, leaving some moisture inside, but then the moisture inside the resin particles evaporates and hardens due to the high temperature. The tendency to break the resin and significantly reduce the strength of the resin increases, and as a result, the glass short MIA of the product
The restoring power of the fiber mat decreases.

On the other hand, if the air introduced into the raw mat 34 is dry, low-humidity air, when the dry air passes through the raw mat 34, it simultaneously carries away the hot and humid air inside the raw mat 34, leaving the raw mat 34 dry. The interior is replaced with a low-humidity air layer. Therefore, even if the mat is subsequently exposed to the outside air, no dew condensation will occur.

Then, in this state, the mat is sent to the oven 21, and the resin particles with reduced moisture are heated and hardened to firmly bond the ams together.

If the water content in the resin granules is low in this way, heating in the oven can be done quite rapidly, so the length of the oven can be shortened, and the resin also functions well as a binder. The resiliency required for product mats (the ability to return to the original thickness after compressing the mat to a certain thickness) is also increasing.

Note that the dry air used has an absolute humidity lower than the absolute humidity of the atmosphere inside the cotton collecting bed 28, preferably lower than the saturated humidity at the outside air temperature, and is about the same as the dew point of the atmosphere inside the cotton collecting bed 28, or Alternatively, it is preferable to have a high temperature of 150° C. or higher. This dry air can be obtained, for example, by heating outside air.

Specific examples will be described below.

Example 1 When manufacturing a glass fiber mat with a density of 10 kg/m' and a nominal molding thickness of 100 mm (7), 100 mmAq of air was introduced into the housing 40 at 300 rn' using the example apparatus shown in FIGS. 1 to 4. L from the opening 42.
It squirted in the direction. Note that FIG. 6 is a plan view of the housing 40 showing the arrangement and dimensions of the openings 42, and as shown, 27 circular openings each having a diameter of 50 mm were opened in a staggered manner.

After increasing the thickness of the raw glass fiber mat using the apparatus of this embodiment, it was introduced into the heat treatment furnace 38 to produce a glass IaAII mat having a thickness of 160 mm. This glass fiber mat is compressed to a thickness of 10 mm and
The restored thickness when this compressive force is released after a day has passed is 133
It was mm.

Comparative Example 1 On the other hand, a glass fiber mat was produced in the same manner as in Example 1 except that the introduction of air into the housing 40 was stopped and the thickness of the green mat was not increased. The restored thickness of this glass fiber mat after compression similar to the above is 1
It was 30mm. As described above, according to the method and apparatus of the present invention, a glass fiber mer 2 with a large restored thickness of about 3 mm can be produced.
We were able to manufacture

In addition, the method and apparatus of the present invention can also be used to form and manufacture mats of rock wool, slag wool, alumina fibers, potassium titanate fibers, carbon fibers, or metal fibers in addition to glass fiber mats.

[Effects] As described in detail below, according to the present invention, it is possible to produce an inorganic fiber mat that has an extremely high restoring ability when a compressed package is unpacked. Therefore, it is possible to increase the degree of compression during packaging and transport the product in a smaller volume, thereby making it possible to reduce transportation costs.

[Brief explanation of the drawing]

FIG. 1 is a longitudinal cross-sectional view showing the structure of an inorganic fiber mat according to an embodiment of the present invention, FIG. 2 is a cross-sectional view showing an enlarged main part of the embodiment device of FIG. 1, and FIG. 3 is a cover body. Perspective view of 40, No. 4
The figure is a perspective view of the inner body used in different embodiments, Figure 5 is a sectional view showing the main parts of the configuration of the device of different embodiments, and Figure 6 is the opening arrangement and dimensions of the upper surface of the housing used in Example 1. FIG. 20... Fiberization means, 24... Spray nozzle,
28...Cotton collecting granite, 30...Cotton collecting conveyor,
32...Suction,' 34...Raw mat, 3
8... Heat treatment furnace, 40... Straddle body, 42... Opening. Agent: Patent Attorney Tsuyoshi Shigeno 2nd Figure 3! ! 1ll s 4 figure

Claims (11)

[Claims] (1) Spraying a binder on the fibers of the inorganic heat-softening substance that have been thinned by a fiberizing means, collecting the fibers on a cotton collection conveyor to form a raw mat of inorganic fibers, and introducing this raw mat into a heat treatment furnace. A method for producing an inorganic fiber mat comprising a step of heat treatment, the method comprising introducing air into the raw mat to increase the thickness of the raw mat, and then introducing the raw mat into a heat treatment furnace. (2) Manufacturing the inorganic fiber mat according to claim 1, wherein the method for introducing air into the raw mat is a method of blowing an air flow onto the raw mat from below to introduce air into the raw mat. Method. (3) The method of introducing air into the raw mat is a method of sucking air above the raw mat and causing the air to flow into the raw mat. Production method. (4) The method for producing an inorganic fiber mat according to any one of claims 1 to 3, wherein the air introduced into the green mat is low-humidity air. (5) A fiberizing means for fiberizing a heat-softening inorganic material that can be made into fibers, a spray nozzle for spraying a binder onto the fibers of the heat-softening material that has been made into fibers, and a collection of the fibers sprayed with the binder. Manufacture of an inorganic fiber mat having a cotton collection box for cotton collection, a cotton collection conveyor provided at the bottom of the cotton collection box, and a suction box provided on the opposite side of the cotton collection box from the cotton collection box. Production of an inorganic fiber mat, characterized in that the apparatus is provided with air blowing means or suction means for introducing air into the green mat deposited on the cotton collection conveyor and coming out of the cotton collection box. Device. (6) The inorganic fiber mat manufacturing apparatus according to claim 5, wherein the air blowing means or suction means is provided opposite to the conveying surface of the cotton collection conveyor. (7) The air jetting means has a housing whose upper surface is placed opposite to the lower surface of the cotton collecting conveyor, and an air jetting port is provided on the upper surface of the housing. An apparatus for producing an inorganic fiber mat as described in 2. (8) The apparatus for manufacturing an inorganic fiber mat according to claim 7, wherein the air outlet is a plurality of spot-shaped openings. (9) The apparatus for manufacturing an inorganic fiber mat according to claim 8, wherein the spot-shaped openings are arranged in a staggered manner. (10) The apparatus for producing an inorganic fiber mat according to any one of claims 6 to 9, wherein the air blowing means includes a low-humidity air supply means connected to the enclosure. (11) The apparatus for producing an inorganic fiber mat according to claim 5, wherein the air suction means has a suction port that opens opposite to the upper surface of the cotton collection conveyor.