JPH0228445B2 - KOBUTSUSHITSUSENIBANNOSEIZOHOHO - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing mineral fiberboard having a moth-eaten pattern and a large number of small pores mixed on the surface.

(Prior art and its problems) Mineral fiberboard is widely used as ceiling materials and other building materials because it has excellent fire retardant properties, heat insulating properties, and sound absorbing properties.

The manufacturing method for such mineral fiberboard is as follows:
Generally, a continuous wet papermaking method or a paste method is known.

However, while the former continuous wet papermaking method has the advantage of producing mineral fiberboard with high bending strength, it has the disadvantage of poor cosmetic properties because the surface is patternless. Although moth-eaten patterns have been formed using methods such as the above, the pattern is unnatural because it is applied mechanically, and it is necessary to combine various processes to create a more natural pattern.

On the other hand, according to the latter paste method, a large number of natural-looking pores are obtained on the surface of the fiberboard, resulting in excellent cosmetic properties, but the mineral fiberboard obtained by this method has a low bending strength. There are problems in that it is small and cannot be continuously produced.

Therefore, if a pattern is formed by a paste layer on a fiber substrate obtained by drying the mineral fiber mat obtained by the former continuous wet papermaking method, a mineral material with high mechanical strength and good design can be obtained. A fiberboard should be obtained, but because the viscosity of the paste used in the paste method is extremely high, it is difficult to form a paste layer integrally on the surface of the fiberboard. Because of this, there were problems such as the fact that manufacturing was time consuming and continuous production was not possible.

(Object of the Invention) The present invention has been made in view of the above-mentioned problems, and is made of a fiberboard that has excellent mechanical strength and has a moth-eaten concave pattern on the surface that has a rich natural shape. The present invention provides a method for manufacturing mineral fiberboard that can be manufactured continuously and efficiently.

(Structure of the Invention) In order to achieve the above object, the method for manufacturing a mineral fiberboard according to the first aspect of the present invention includes fine air bubbles on a wet mineral fiber mat obtained by a continuous papermaking method. A mineral fiber paste layer is provided, and the surface of this paste layer is rubbed by a roll rotating at a peripheral speed different from the conveyance speed of the mineral fiber mat to form a zigzag pattern. , and the method for manufacturing a mineral fiberboard according to the second invention, after forming the staggered pattern with the rolls,
Alternatively, prior to formation, a mold material having convex portions such as pins is pressed against the surface of the paste layer to form a large number of concave patterns on the surface of the paste layer, thereby creating a worm-eaten pattern with openings of arbitrary shapes, and then heating. , which is characterized by drying.

(Example) To explain an example of the present invention with reference to the drawings, it is mainly made of mineral fibers such as rock wool and slag wool, and if necessary, appropriate aggregates and waste paper pulp are mixed therein, and starch is further added. A slurry prepared by adding an appropriate amount of a binder such as the above is subjected to continuous wet paper-making by a conventional method using a known means such as a round net paper machine or a Fourdrinier paper machine to obtain a wet mineral fiber mat 1.

On the other hand, mix mineral fibers with appropriate amounts of binders such as starch, thickeners, and blowing agents if necessary, add 180 to 250 parts of fresh water to 100 parts of the solid content of this mixture, and knead to finely form the fibers. A paste containing air bubbles is obtained.

In this example, the above-mentioned thickener used in kneading the mineral fiber paste is a relatively high-viscosity type (for example, SCP3000
~5000) are used.

Incidentally, the thickener originally has the property of easily entrapping air bubbles during stirring, and this bubble entrapment phenomenon becomes more pronounced when the agent is stirred strongly, and it also functions as a foaming agent.

Usually, the thickener is added gradually by stirring at low speed. Although the present invention is of course not limited to this, the above-mentioned bubble entrapment phenomenon due to strong stirring is mainly utilized.

In addition, when using a thickener with the function of a blowing agent as mentioned above, the mineral fiber solid content of the mixture
When adding 180 to 250 parts of fresh water to 100 parts,
The paste has a semi-wet curled shape with holes remaining in the curled fibers, and if a thickener is added in this state, the air bubbles in the paste will be encapsulated, and the air bubbles will be contained in the paste without dissipating. Become.

In addition, as blowing agents that may be used as necessary,
For example, inorganic foaming agents such as carbonates (heavy carbonate, sodium bicarbonate, etc.), ammonium salts, PVC, EVA, PE, phenol, etc.
There are foamable synthetic resins that react at 150℃. still,
A blowing agent such as a carbonate that generates gas is used in conjunction with a thickener to prevent air bubbles from dissipating; in this case, the thickener is added at 1 to 2% by weight based on the mineral fiber solids of the mixture; It is desirable to mix the agent in an amount of 1% by weight or less.

Although it depends on the amount of thickener mixed, if the paste mainly composed of mineral fibers has a lower viscosity than the paste used in the normal paste method, it will not work well in the next process if left as is. Since it is difficult to obtain a moth-eaten pattern, a foaming agent is added as described above to create a paste containing fine air bubbles.

Note that it is preferable that the air bubbles be adjusted to 10 to 15% of the volume of the paste.

In addition, if the water content in the paste is low, it will be difficult to layer the paste layer on the mineral fiber mat, and if the water content is high, the air bubbles will be retained even if a fine uneven pattern is formed by the air bubbles contained in the paste. Since it is not possible to obtain a pattern with a design effect, the moisture content is adjusted to the above-mentioned range.

The first invention is to apply the mineral fiber paste whose water content has been adjusted in this way onto the surface of the undried mineral fiber mat 1 obtained by the continuous wet papermaking method during the transportation of the mat 1. The paste layer 2 is coated to form a paste layer 2 of an appropriate thickness, and this paste layer 2 is rubbed with a roll 5 rotating at a circumferential speed different from the conveyance speed of the mineral fiber mat 1 to form a moth-eaten pattern. It is something to do.

That is, the roll 5 rotating at a peripheral speed different from the conveying speed of the mineral fiber mat 1 transfers the paste layer 2.
When the surface layer of the paste was rubbed, the moving speeds of the surface layer of the paste being rubbed and the lower layer of the paste that was not being rubbed were different, and the surface layer was torn from the weak parts at many points on the surface, opening diagonally upward (4a). A staggered pattern 3a is formed.

In addition, the paste contains fine air bubbles, which create many small holes 8 on the surface of the paste layer.
A pattern is obtained in which the large number of holes 8 and the large moth-eaten random pattern formed by the staggered pattern are mixed together.

After forming a pattern on the paste layer 2 in this way, the mineral fiber mat 1 having the paste layer 2 is dried to obtain a mineral fiber board.

The obtained mineral fiberboard has a raised portion 9 formed by rubbing the roll 5 around the opening of the staggered pattern.
, so if necessary, it can be ground and removed to make the surface flat.

Next, the second invention provides an embossing roll or an embossing roller having convex portions 7 such as a large number of pins on the surface while the paste layer 2 is rubbed on the surface of the paste layer 2 with the roll 5 and the paste layer is not dried. By pressing a shaped material 6 such as a plate onto the surface of the paste layer 2 at a depth such that the convex portions 7 do not reach the mineral fiber mat 1, a concave pattern is formed in the paste layer 2 in an arbitrary shape, and the above-mentioned rubbing A moth-eaten pattern is formed by combining the zigzag pattern.

In this case, the formation of the concave pattern 3b by the mold material 6 is as follows:
The uneven pattern 3a may be formed before or after the uneven pattern 3a is formed by the rubbing of the roll 5.
If the concave pattern 3b is formed before the formation of the concave pattern 3b, the concave pattern 3b is expanded by the convex portions 7 of the mold material 6.
The shape of the opening 4b of b is deformed by the rubbing by the roll 5, and a more natural-looking moth-eaten concave pattern 3 is obtained. When the concave pattern 3b is formed using the mold material 6, the uneven pattern 3a previously formed using the roll 5 is torn and misaligned inside the paste layer. The opening part of the pattern is partially continuous with the concave pattern 3b formed by the convex part 7 of the mold material 6, and the part where both the patterns 3a and 3b are continuous and large and the discontinuous concave pattern part is striped. It is possible to obtain a three-dimensional decorative surface that is closer to a natural moth-eaten pattern, which is amorphous and rich in variation, with a large concave pattern and a small concave pattern formed by discontinuous parts.

Note that the shape of the concave pattern 3b formed by the shape material 6 is a convex shape so that it is formed into an elongated shape in a direction substantially parallel to the sliding pattern 3a formed by the rubbing of the roll 5, that is, along the width direction of the mineral fiber mat 1. By setting the shape of the portion 7 in advance, it is possible to create a natural connection between the concave patterns.

Furthermore, if pressing is performed using the mold material 6 after forming the staggered pattern 3a with the roll 5, the adhesion between the paste layer 2 and the mineral fiber mat 1 as the lower layer is improved.

In this way, a moth-eaten concave pattern 3 is formed on the paste layer 2 of the mineral fiber pine 1, which is a combination of a sliding pattern and a concave pattern caused by pressing, and then heated, dried, and sanded as necessary. to obtain mineral fiberboard.

(Effects of the Invention) As described above, the method for manufacturing a mineral fiberboard according to the present invention includes providing a mineral fiber paste layer containing fine air bubbles on a wet mineral fiber mat obtained by a continuous papermaking method, Since the surface of this paste layer is rubbed by a roll whose circumferential speed is different from the conveyance speed of the mineral fiber mat, the surface of the paste layer is randomly scraped and changed by the rubbing of this roll. It is possible to form a zigzag pattern with a rich shape, and in addition, many small pores are formed on the surface due to the air bubbles contained in the paste.
These patterns and holes make it possible to obtain a moth-eaten pattern with a natural feel.

In addition, it is possible to form a pattern on the mineral fiber mat using a roll in a series of steps, making continuous mass production possible.Furthermore, in order to form a paste layer on the mineral fiber mat in a wet state, The binder acts as the moisture content decreases during drying, making it possible to firmly integrate the two without using an adhesive.Furthermore, the mineral fiber mat and the paste layer can be dried at the same time. This allows for energy savings.

In addition, the obtained mineral fiberboard has high bending strength because the pine substrate is formed by a continuous wet papermaking method, and the natural moth-eaten pattern is obtained on the surface, giving it excellent cosmetic properties. It is something that can be demonstrated.

Further, in the method of the second invention, after or prior to forming the staggered pattern with a roll, a mold material having a convex portion such as a pin is pressed against the surface of the paste layer to form an opening of an arbitrary shape on the surface of the paste layer. It is characterized by providing a moth-eaten concave pattern and then heating and drying it, so that the paste layer, which contains moisture and has appropriate fluidity, forms a concave pattern on the convex parts of the mold material. Of course, the mold material can be pushed into and pulled out of the layer smoothly,
Unlike the conventional method of forming a pattern by pressing the surface of a paper-made board with a mold material to destroy the surface, a concave pattern having openings of any shape and size can be formed without reducing strength. The continuous and discontinuous portions of this concave pattern and the scratched pattern caused by the rubbing of the rolls make it possible to obtain a moth-eaten concave pattern with an irregular shape and a rich natural feel.

Furthermore, the difference in the density of the scratched pattern caused by rubbing can be compensated for by adding a concave pattern caused by the pressing of the mold material, thereby making it possible to stabilize the cosmetic properties.

[Brief explanation of drawings]

The drawings show embodiments of the present invention; FIG. 1 is a simplified side view, FIG. 2 is a sectional view showing a state in which a zigzag pattern is formed, and FIG. 3 is a mineral fiber pine with a zigzag pattern and a concave pattern formed thereon. FIG. 4 is a partial perspective view of the obtained mineral fiberboard. 1...Mineral fiber matte, 2...Paste layer,
3a...Zurashi pattern, 3b...Concave pattern, 4...Opening, 5...Roll, 6...Shape material, 7...Protrusion.

Claims (1)

[Claims] 1. A mineral fiber paste layer containing fine air bubbles is provided on a wet mineral fiber mat obtained by a continuous papermaking method, and the surface of this paste layer is A method for manufacturing a mineral fiberboard, characterized by forming a zigzag pattern by rubbing with rolls rotating at different circumferential speeds. 2. A step of providing a mineral fiber paste layer containing fine air bubbles on the wet mineral fiber mat obtained by the continuous papermaking method, and a step of forming the surface of this paste layer at a peripheral speed different from the conveyance speed of the mineral fiber mat. There is a step of rubbing with a rotating roll to create a staggered pattern with irregularly shaped openings, and a process of pressing a shape material with convex parts such as pins onto the surface of the paste layer to create a large number of concave patterns on the surface of the paste layer. a step of forming;
A method for manufacturing mineral fiberboard characterized by continuously performing the steps of patterning and drying.