JPS6256302B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a construction board having a raised pattern and a method for manufacturing the same.

2. Description of the Related Art Decorative boards, in which a textured pattern is provided on the surface of soft fiberboard or inorganic fiberboard, are conventionally known as interior materials for buildings. This decorative board can be manufactured by forming an uneven pattern on the fiberboard surface by pressing a heated embossing roll or embossing plate, by cutting the fiberboard surface, or by cutting the fiberboard surface. There are methods such as stacking.

However, in any of the above conventional methods, after the fiberboard is formed, the surface of the fiberboard is embossed, cut, or laminated, which is a time-consuming process. There was a drawback.

The present invention has been made in view of the above-mentioned drawbacks of the conventional art, and provides a construction board that can be pressure-formed and at the same time form a raised pattern on its surface without requiring the labor and effort required in the past, and a method for manufacturing the same. This is what I am trying to do.

Next, the present invention will be explained with reference to the accompanying drawings, which are one embodiment of the present invention.

FIG. 1 shows an apparatus to which the method of the present invention is applied,
Reference numeral 1 denotes a freely rotatable roller, and a conveyor belt 2 is stretched over the upper surface of the roller 1, and the conveyor belt 2 is moved in directions indicated by arrows 3 in the figure by a motor (not shown). A hopper 4 is provided above the conveyor belt 2, and a roll 5 having a scraper plate 5a is provided on the lower surface of the hopper 4, and the roll 5 is rotated in the direction of an arrow 6 by a motor (not shown). Next to the hopper 4, a spreader (not shown) for a mixture of an inorganic fiber such as rock wool and a binder such as a phenolic resin is provided above the conveyor belt 2. Next to the spreader, a pressure roll 7 is provided above the conveyor belt 2, and the pressure roll 7 is rotated in the direction of arrow 8 in the figure by a motor (not shown).

Next to the press roll 7, a drying oven 9 is provided,
Inside the drying oven 9, there is provided a press machine 10 consisting of an upper and lower pair in which a caterpillar-shaped endless strip 12 is stretched between rotating rollers 11, 11, and a motor drives the endless strip 12 in the direction of arrow 13 in the figure. It is designed to rotate. Note that the inside of the drying oven 9 can be heated to an appropriate temperature.

The press machine 14 in the figure is a device used when the drying oven 9 is not used, and the press plate 1 is heated by a heat source.
5 can be heated.

Note that 16 is a lump of fibers having springback force (hereinafter referred to as springback material), and 17 is a mixture of inorganic fibers such as rock wool and a binder such as phenol resin as appropriate. .

Next, a method for manufacturing a construction board using the apparatus having the above configuration will be described.

In FIG. 1, the conveyor belt 2 is moved in the direction of arrow 3 in the figure. Next, the roll 5 of the hopper 4 is rotated, and the springback material 16 placed in the hopper 4 is scraped off with a scraping plate 5a provided on the outer peripheral surface of the roll 5. By this scraping, the springback material 16 is scattered onto the conveyor belt 2 from the lower surface of the hopper 4. At this time, it is preferable to suction the springback material 16 from below the conveyor belt 2 using a suitable suction device and hold it on the upper surface of the conveyor belt 2. Continuing, when the conveyor belt 2 carrying the springback material 16 moves and comes below a spreader (not shown), the compound 17 is spread by the spreader, and the mixture 17 is spread on the conveyor belt 2 and the springback material 16. They are stacked on the top surface in a mat shape with an appropriate thickness. In this case, it is preferable to suck the compound 17 from below the conveyor belt 2 using an appropriate suction device and hold it on the upper surface of the conveyor belt 2, as in the case of spreading the springback material 16 described above.

In addition, as for the above-mentioned compound 17, a solution binder may be sprayed onto the inorganic fibers in advance before being sprayed, or a binder in the form of a powder may be mixed with the inorganic fibers. It can be something. Further, the springback material 16 or compound 17 may be colored in an appropriate color.

Next, when the conveyor belt 2 carrying the springback material 16 and the compound 17 moves and comes below the press roll 7, the press roll 7 transfers the springback material 1 placed on the upper surface of the conveyor belt 2.
6 and blend 17 are compressed to an appropriate thickness. The purpose of this compression is to facilitate the next step of press working by compressing the material to an appropriate thickness in advance.

As mentioned above, the springback material 16 and compound 17 compressed to an appropriate thickness are sent from the conveyor belt 2 to the drying oven 9 by the movement of the conveyor belt 2, and are supplied to the press machine 10 in the drying oven 9. Ru. The supplied springback material 16 and compound 17 are pinched between the endless strips 12 and 12 by the rotation of the endless strip 12, and are compressed to a predetermined thickness. At this time, heated air is sent through the holes 12a provided in the endless strip 12 to form the mixture 17.
The plate-shaped body 18 is formed by continuously curing the binder.

The formed plate-like body 18 is continuously fed out from the press 10 in the right direction in the figure by the rotation of the endless strip-like body 12, and is cut into a fixed length and width.

When a thermosetting resin or a hot melt type resin is used as the binder, it is necessary to heat and pressurize it. In addition, when using synthetic fibers such as nylon for the spring back material 16,
Pressure is applied at room temperature.

In the above, the plate-shaped body 18 is continuously formed by the press machine 10 in the drying oven 9, but instead of this, the springback material 16 and the compound are compressed to an appropriate thickness by the press roll 7. After cutting 17 into a certain length and width, it may be sent from the conveyor belt 2 to the press 14, and may be compressed by the pressing plate 15 of the press 14 to a predetermined thickness. In this case, as in the case of the press machine 10, the binder of the compound 17 is cured at room temperature or heated, and the plate-shaped body 18 is formed. After that, the pressing plate 15
The pressing force is released and the plate-like body 18 is taken out from the press 14. The above press machine 10, 14
When the plate-like body 18 is pressurized by the first
As shown in Fig. 2, spring back material 1
Since the particles 6 are scattered on the surface of the plate-like body 18, their volume is reduced by the pressure of the endless strip-like body 12 or the pressing plate 15, and they become flush with the surface of the plate-like body 18. When the endless strip 12 is rotated to be fed out of the press 10 and the pressing force is released, or when the pressing force of the pressing plate 15 is released, the springback material itself releases the binder, as shown in FIG. Since the spring back material 16 does not have any fibers, its lower surface is buried and fixed in the plate-like body, but due to the elastic force of the fibers, the spring back material 16
The volume of the springback material 16 increases, and a portion of the springback material 16 protrudes upward from the surface of the plate-shaped body 18 to form a convex portion 20.
form. As a result, a building board 19 having a raised pattern formed on its surface is obtained.

In addition, in the portion of the springback material 16 embedded in the plate-shaped body 18, when the binder of the compound 17 hardens, the binder may adhere slightly to the contact surface of the springback material 16 that comes into contact with the compound 17. As it penetrates, it is bonded together with the fibers of Formulation 17.

The spring back material 16 is a lump of inorganic fiber such as rock wool or glass wool, synthetic fiber such as nylon or polypropylene, vegetable fiber such as hemp or cotton, or animal fiber such as wool. It has various shapes such as , granular, wire, band, and net shapes, and is a state in which the so-called fibers are intertwined so as to have a springback force.

Among the above fibers, the springback material 16 is
For non-inorganic fibers, especially synthetic fibers, it is not suitable to heat and pressure mold them, and it is necessary to use a room temperature curing binder and pressure mold them at room temperature or at a temperature below the fiber's softening point. There is.

The above springback material 16 or compound 17
The plate-shaped body 18 may be colored in advance, or a desired decoration may be applied to the plate-shaped body 18 after molding.

In the above embodiment, the pressing plate 15 has a flat plate shape, but the pressing plate 15 is not limited to this, and may have a curved surface.

Next, the results of experiments conducted by the inventor will be explained.

Rock wool granular cotton with a diameter of about 50 mm is sprinkled as a springback material, and a blend of rock wool fibers with 7% (weight) of phenol resin added as a binder is sprinkled on the rock wool granular cotton and piled up to form a mat. Next, the formed pine is compressed with a flat pressing plate of a press machine, and
The mat was heated to a temperature of 180° C. for 9 minutes to cure the binder of the formulation and form a plate. After that, when the pressing force from the pressing plate is released, the fibers of the compound containing the binder have been cured, but the springback material exposed on the plate surface has not been cured because no binder has been added. An architectural board was obtained in which the springback material increased due to the springback force and a raised pattern with a height of about 3 mm was formed on the surface of the plate.

As is clear from the above explanation, according to the present invention, the compound and the springback material spread on the surface are pressurized together to form a plate-shaped body, and the springback material is formed by releasing the pressing force. Since the convex portions are formed on the surface of the plate-shaped body, it is possible to easily create a raised pattern without requiring other processes such as embossing or cutting after forming the plate-shaped body as in the conventional method. It is possible to obtain a construction board having: By coloring the springback material, the fibers of the compound, or the binder in advance, it is possible to obtain a decorative board with a raised pattern at the same time as forming the plate. When painting the surface of a plate after forming a plate, the hardened compound part and the uncured springback material part may have uneven paint absorption and different adhesion. A decorative board with various shades of color and a variety of appearances can be obtained. Furthermore, even if the springback material and the compound are made of different types of fibers, the same decorative laminate as above can be obtained. Furthermore, since the springback material is exposed on the surface, a decorative board with a soft feel can be obtained. Furthermore, when used as an interior material, the uncured springback material has the effect of improving sound absorption performance.

[Brief explanation of the drawing]

FIG. 1 is a side sectional view showing an apparatus to which the method of the present invention is applied, FIG. 2 is a sectional view showing a state in which it is pressurized by a press, and FIG. It is a diagram. DESCRIPTION OF SYMBOLS 10, 14...Press machine, 16...Springback material (fiber mass), 17...Blend, 18...Plate-shaped body, 19...Architectural board, 20...Convex part.

Claims (1)

[Scope of Claims] 1. On the surface of a plate-shaped body made of a mixture of inorganic fibers such as rock wool and glass wool with a binder such as phenol resin, the lower end is embedded in the plate-shaped body and the upper part is plate-shaped. A construction board characterized by being dotted with aggregates of fibers that protrude from objects. 2. Spread a mixture of inorganic fibers such as rock wool or glass wool and a binder such as phenol resin on the upper surface of a mass of fibers having springback force, which has been dispersed as appropriate, and stack the mixture to an appropriate thickness, and then press using a press. After forming a plate by applying pressure integrally with the lump, and releasing the pressure, on the surface of the plate,
1. A method for manufacturing a construction board, which comprises increasing the size of the lumps by the springback force of the fibers to form convex portions.