KR100683806B1 - Mineral fiber mat and manufacturing method therefor - Google Patents

Abstract

A cut mineral fiber mat and a manufacturing method thereof are provided to disperse uniformly the fibers cut from a cutting roller at the short falling distance. Cutting and dispersion processes are performed by a cutting roller member(4) and a dispersion device(14). At the cutting roller member, a cutting roll having edges installed at every distance is engaged with a roll made of urethane materials and constructed by one cutting roller member. The cutting roll has the length similar to that of a transfer belt(18) located at the lower portion of the cutting roller member. Injection openings with one-inch distance are formed at the cutting roller member lengthwise.

Description

Cutting inorganic fiber mat and its manufacturing method {MINERAL FIBER MAT AND MANUFACTURING METHOD THEREFOR}

1 is a schematic view of a cutting inorganic fiber mat manufacturing process according to an embodiment of the present invention,

Figure 2 is a block diagram of the device for cutting and dispersing the fiber of Figure 1,

3a and 3b is a photograph showing a glass fiber and basalt fiber dispersed state,

Figure 4 is an exemplary view applied to the cutting inorganic fiber mat of the present invention.

The present invention relates to an improvement of a cutting inorganic fiber mat and a method for producing the same.

Inorganic fiber filaments are used to reinforce materials, especially polymer materials, which have properties that do not serve their purpose without inorganic fiber filaments. Inorganic fibers for reinforcement are generally glass fibers, but basalt fibers are also applicable.

 Cutting inorganic fiber mat is a mat produced by cutting to a certain length in the range of 50 ~ 200mm, evenly sprayed on the transfer belt and then treated with adhesive.

However, the adhesive applied to the cut inorganic fiber mat is an important component in maintaining the shape of the mat, and the type of adhesive applied may be classified into a web binder, a liquid adhesive, and a powder adhesive.

Cutting inorganic fiber mat is different in the structure and processing conditions of the facility according to the type of adhesive applied, and the manufacturing method according to the type of adhesive applied is an example as follows.

First, the web adhesive is applied as follows.

In the material supplying section, the glass fiber is cut to a certain length (50 to 200 mm) to first disperse (30 to 170 g / m 2) onto the conveying belt, and the web adhesive is disposed on the dispersed glass fiber. The glass filament is cut into a predetermined length (50 to 200 mm), and then divided into secondary dispersions (30 to 170 g / m 2) to the upper surface of the web binder. The uniformly distributed and stacked materials are moved to a heating section, where the adhesive is heated to a high temperature while being pressed between the upper and lower sides of the dispersed fiber between the belts of Teflon material, which are not easily bonded, and are simultaneously compressed. The hot pressed glass fiber is wound in a roll shape while maintaining the shape of the mat by the adhesive force of the web adhesive. When the web adhesive is applied, not only the adhesive can be uniformly supplied but also a low-weight mat of 100 to 200 g / m 2 can be easily produced as compared with the application of the liquid adhesive or the powder adhesive.

However, the web adhesive applied to manufacture the cut fiber mat as described above is not produced in the country, and since the whole must be procured from abroad, there is a problem that the price of the product is increased.

Next, when the liquid or powder adhesive is applied as follows.

Cutting and dispersing the long glass fiber to a certain length (50 to 200 mm), spraying a liquid or powdered adhesive on the dispersed glass fiber, melting the adhesive while the glass fiber in the state where the adhesive is attached passes through the heating furnace In the step, the fiber is divided into a step of completely curing the adhesive on the surface of the fiber by a cold press roller and winding the roll into a roll shape.

Some domestic companies manufacture polyester fiber-based cutting adhesives to produce 200-600 g / m2 chopped fiber mats, but in order to produce low-weight mats of 200 g / m2 or less, 30-50 tex / strand glass fibers are used. When dispersed at a level of 100 to 200 g / m 2 on the conveyance belt, voids are formed between the dispersed fibers and the fibers. When the powder adhesive is dispersed onto the fibers, the powder adhesive does not settle on the surface of the fibers, Escape into the voids.

Therefore, when the mat is manufactured by applying the powder adhesive as described above, in spite of the excellent properties of the produced mat, there is a problem that it is difficult to apply the powder adhesive in the production of low-weight cut fiber mat of 200g / ㎡ or less .

Finally, the process of applying the liquid adhesive is as follows.

When dispersing the liquid adhesive in the dispersed fibers, due to the viscosity of the liquid adhesive, it is easily adhered to the surface of the fiber to be used not only for the production of mats of 200 g / m 2 or more, but also for the production of low-weight (100-200 g / m 2) mats. Can be. Epoxy resins and other acrylic resins may be used in the case of liquid adhesives, solvents such as toluene and thinner in the case of oil-based adhesives, and water diluted in the case of aqueous adhesives. When the liquid adhesive is applied, it is easily penetrated between the dispersed fiber and the fiber, and there is an advantage that a uniform supply of the liquid adhesive is possible with the dispersed fiber.

However, when the liquid adhesive is applied, the tensile strength and the stiffness of the shaped mat are weaker than when the powder adhesive such as polyester is applied. In addition, after shaping the cut fiber mat using an acrylic liquid adhesive, in order to reinforce the strength of the polymer material such as polyurethane, when the polymer material is bonded by an adhesive such as isocyanate or MDI, the cut fiber mat is There is also a problem in that the adhesion between the liquid adhesive and the polymer material is weak due to the low affinity between the liquid adhesive applied to shape the cutting fiber mat and the adhesive used to bond the polymer material. In addition, in the case of the liquid adhesive, it is pointed out as a storage problem, the life expectancy is significantly reduced compared to the powder adhesive.

On the other hand, general inorganic cut fiber mat is first cut glass or basalt fibers in a cutting device by cutting to a certain length of 5 to 20cm and freely falling on the conveying belt, to be dispersed on the conveying belt. In the process of applying the domestic liquid adhesive, the cutting device is composed of 7 to 10 pairs of cutting rollers, and each roller device is a roller and blade equipped with blades at regular intervals to cut the fibers at regular intervals. The rollers of urethane skin material are paired so that the fiber can be cut by being engaged with the mounted roller. When there are 7 to 10 pairs of cutting rollers at the cutting section, there is a gap of 20 to 30 cm between each roller and the rollers. Since about 3m above the belt can be installed at a height, the fiber cutting and dispersing sections are asymmetrically enlarged with respect to the entire construction equipment, and occupy a lot of space. Therefore, operation of the facility in the confined space becomes difficult.

Accordingly, an object of the present invention is to provide a manufacturing method capable of producing not only chopped inorganic fiber mats of 300 to 500 g / m2 but also low weight chopped inorganic fiber mats of 100 to 300 g / m2 while using a powder binder, and a chopped fiber mat thereof. .

Another object of the present invention is to provide a cutting inorganic fiber mat manufacturing method and a cutting fiber mat thereof so that the fibers cut from the cutting roller can be uniformly dispersed even in a short falling distance.

In accordance with the above object, the present invention, the inorganic fiber yarns are cut into one cutting roller portion having a length similar to the width of the lower conveying belt and then dispersed with a disperser, low weight open fiber of 100 ~ 300g / ㎡ on the conveying belt It is characterized by producing a mat by drop distribution, by spraying water on the surface of the dispersed low-weight open fiber yarns to increase the adhesive force, and then spray spraying the powder binder, and then heating and cooling compression.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be noted that the same elements in the figures are represented by the same numerals wherever possible. In addition, detailed descriptions of well-known functions and configurations that may unnecessarily obscure the subject matter of the present invention will be omitted.

1 is a schematic view of a process for manufacturing a cutting inorganic fiber mat according to an embodiment of the present invention, using an inorganic long fiber yarn (2), such as glass fiber or basalt fiber, fiber cutting and dispersion process (S1), water spray process (S2), through the powder adhesive dispersion spraying process (S3), the heating process (S4), and the cold pressing and winding process (S5) to produce a cut inorganic fiber mat (44).

FIG. 2 is a block diagram illustrating a specific device for performing the fiber cutting and dispersing process corresponding to S1 in FIG. 1. The fiber yarn is configured to be uniformly dispersed even in a short drop distance of about 1mm.

Referring to Figure 2, the cutting roller portion 4 is configured such that the cutting roll 8, the blade 10 is installed at regular intervals in the longitudinal direction of the cylindrical surface to be engaged with the roll 6 of the urethane material, the existing and Alternatively, it is configured to have only one cutting roller portion and has a length (for example, 1500 mm to 1700 mm) similar to the width of the conveying belt 18 located below the cutting roller portion 4. And at the upper end of the cutting roller portion 4, for example, by forming the openings of 1 inch intervals in the length direction of the cutting roller portion 4, it is provided so that the multiple strands of inorganic long fibers (2) can be introduced at once through the openings. .

The lower part of the cutting roller portion 4 is provided with a pair of dispersers 14 having a structure as shown in FIG. 2, and serves to disperse the fibers cut in the cutting roller portion 4.

In the embodiment of the present invention with the configuration of the cutting roller portion 4 and the disperser 14 as described above, even if the cutting roller portion 4 is positioned so that only about 1 m high from the conveying belt 18 on the conveying belt 18 Since the fibers can be uniformly dispersed and dispersed, this allows the cutting and dispersing sections to be miniaturized.

Referring to FIGS. 1 and 2 again, the process of manufacturing the cut inorganic fiber mat according to the embodiment of the present invention will be described in more detail.

Now, inorganic fiber yarns 2, such as glass fiber yarn or basalt fiber yarn, which have undergone a roving process are introduced through the inlets of the cutting roller portion 4, and the inorganic fiber yarns (by one cutting roller portion 4) 2) Each of them is cut down to a certain length.

Thereafter, the dropped cut fiber yarn 12 is dispersed by the rotation of the disperser 14 and is uniformly dropped and dispersed on the transport belt 18 located below.

The fibrous yarns (hereinafter referred to as "open fiber yarns") 16 uniformly sprayed onto the conveying belt 18 adjust the number of strands of fibrous yarn fed through the inlet and the conveying speed of the conveying belt 18, Not only can be distributed at a density of 300 ~ 500g / ㎡, in particular, it can be distributed as a low-weight open fibers having a density of 100 ~ 300g / ㎡ according to the embodiment of the present invention.

3A and 3B, a low-weight, open-weight fiber that is cut at the cutting roller portion 4 installed at a height of 1 m above the conveying belt 18 and dispersed in the disperser 14 and uniformly distributed in the conveying belt 18. It is showing them.

Figure 3a shows a picture of the open fiber yarn composed of glass fiber yarns having a density of 200g / ㎡, Figure 3b shows a picture of the open fiber yarn composed of basalt fiber yarns having a density of 200g / ㎡.

The cut and dispersed open fiber yarn 16 is wetted by the water 22 sprayed from the water injector 20 while passing through the transfer belt 23 after being transferred by the conveying belt 18. Open fiber yarns wetted by moisture have increased surface tension and increase adhesion.

The open fiber yarns wetted by the moisture are attached to the upper part of the powder binder 26 dispersed and sprayed from the upper powder binder sprayer 24 while passing through the transfer belt 28 of the next stage.

As the powder binder 26, polyolefins, polyesters, polyamides, and the like are mainly used, but other polymer adhesives may be used.

In the case of the powder binder 26, unlike the liquid binder, since it does not have a viscous force, when the powder binder 26 is dispersed in low weight open fiber yarns of 100 to 300 g / m 2, preferably 100 to 200 g / m 2, The powder adhesive 26 does not adhere to the surface of the open fiber yarn and is easily pulled out between the fibers and the pores of the fibers. However, in the embodiment of the present invention, since the wet fibers of the fiber fibers are wetted by water injection before spraying the powder binder, the adhesive force of the fiber surface is artificially increased, so that the low weight of 100 to 300 g / m 2, preferably 100 to 200 g / m 2 Even in the case of open fiber yarns, the powder adhesive is adhesively fixed to the surface of the open fiber yarns.

When the powder binder adheres to the open fiber yarn, the surplus becomes liquid powder binder flowing down into the gap between the fiber and the fiber and the gap of the transfer belt 28, and the transfer belt for collection installed perpendicular to the open direction of the open fiber yarn ( 30), and the collected liquid powder binder is recycled.

After the powder binder 26 is dispersed and sprayed, the powder binder 26 is heated in the heating furnace 32 and cold pressed in the compression cooling roller part 38 to be manufactured into a mat.

More specifically, the open fiber yarns to which the powder binder 26 is attached are melted by the powder binder 26 adhered to the open fiber yarns by the heating furnace 32 while passing through the transfer belt 36. Lose.

Since the open fiber yarns before the powder binder 26 is completely melted can be disturbed even by fine air flow, the heat source of the heating furnace 32 uses a heat transfer device 34 such as a heat transfer rod that does not circulate air. The heat transfer device 34 is set to match the heating temperature and the heating time according to the properties of the powder binder 26 to melt the powder binder 26. For example, in the case where the powder binder 26 is a polyester powder adhesive, it is heated and melted at a temperature of about 200 to 250 ° C. for about 3 to 5 minutes so that the open fibers are bonded.

The open fiber yarns bonded by melting of the powder binder 26 pass through the heating furnace 32 and then pass through the cold press roller part 38 to form a product shape of a certain thickness with complete curing of the melted powder binder. You lose. After passing through the compression cooling roller part 38, the mat of a predetermined width is cut by the circular blade 40 of the edge to become a cutting inorganic fiber mat 44, and then the winder 42 in a roll shape It is wound up and becomes the final product.

4 is a cross-sectional configuration diagram in which the cutting inorganic fiber mat 44 according to an embodiment of the present invention is applied to the production of a vehicle headliner, and the cutting inorganic fiber mat 44 is formed on both sides of the PU foam 50 as a reinforcing material. In addition, the ventilation nonwoven fabric 52 is laminated on both surfaces thereof, and the skin nonwoven fabric 54 is formed on the ventilation nonwoven fabric 52 of one side.

In the above description of the present invention, specific embodiments have been described, but various modifications may be made without departing from the scope of the present invention. Therefore, the scope of the present invention should not be defined by the described embodiments, but should be determined by the equivalent of claims and claims.

As described above, the present invention can manufacture even low-weight chopped inorganic fiber mats of 100 to 300 g / m2 while using a powder binder, and the fibers cut from the cutting roller parts can be uniformly dispersed even in a short falling distance. There is also an advantage in that the dispersion section can be miniaturized.

Claims (3)

The inorganic fiber yarns are cut into one cutting roller section having a length similar to the width of the lower conveying belt, and then dispersed with a disperser, drop-distributing into a low weight open fiber of 100 to 300 g / m 2 on the conveying belt, and the dispersed low weight spreading Method of producing a cutting inorganic fiber mat, characterized in that to spray the water on the surface of the fiber yarns to increase the adhesive force, and then spray spraying the powder binder, and then to heat and cool compression. The method of claim 1, wherein the excess liquid powder binder that adheres to the low weight open fiber by spraying the powder binder dispersion spray and is collected through the collecting belt is installed differently from the conveying direction of the open fiber fibers. Cutting inorganic fiber mat manufacturing method. Cutting inorganic fiber mat produced by the manufacturing method of claim 1.

Images