JPH09201814A - Manufacture of rock wool board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a rock wool board with a small dimensional change at the time of water absorption and a high waterproof strength. SOLUTION: A wet mat 2 is molded by making a sheet of rock wool. Then a thermally curable resin liquid 4 is applied to the surface of the wet mat 2. Further, the wet mat 2 is impregnated with the thermally curable resin liquid 4 by dehydrating the wet mat 2 by absorption from its rear side. In addition, the wet mat 2 is impregnated with the thermally curable resin liquid 4 applied to the front face of the mat 2, while a moisture contained in the wet mat 2 is removed from the rear face of the wet mat 2. Thus, it is possible to uniformly impregnate the wet mat 2 with the thermally curable resin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a rock wool board used as a building material such as a wall material, a ceiling material, an eave ceiling material, a floor material and the like.

[0002]

2. Description of the Related Art Conventionally, calcium silicate boards, insulation boards, particle boards, cement boards, and the like have been used as building materials. Rock wool boards are also effective building materials from the viewpoint of heat insulation and lightness. one of. However, since the rock wool board has a higher water absorption than the other building materials described above, there has been a problem that the dimensional change at the time of water absorption is large and the water resistance strength (bending strength at the time of water absorption) is reduced. Therefore, a rock wool board containing a thermosetting resin has been proposed in order to suppress a dimensional change at the time of water absorption and to improve the water resistance strength.

The rock wool board containing the thermosetting resin is formed by wet-making a rock wool slurry prepared by mixing rock wool and water with a paper making machine to form a wet mat, and then wet. The mat is dried to form a dry rock wool board, a thermosetting resin is applied to the surface of the dry rock wool board to impregnate the dry rock wool board with the thermosetting resin, and then the dry rock wool board is heated. Then, the thermosetting resin is cured.

[0004]

However, since the rock wool board containing the above thermosetting resin is prepared by impregnating the dry rock wool board formed by drying the wet mat with the thermosetting resin, Since the thermosetting resin is not uniformly impregnated, it is possible to suppress the dimensional change when absorbing water and improve the water resistance strength compared to rock wool board that does not contain the thermosetting resin. There wasn't.

The present invention has been made in view of the above points, and provides a method for producing a rockwool board capable of obtaining a rockwool board having a small dimensional change upon absorption of water and high water resistance. The purpose is.

[0006]

According to a first aspect of the present invention, a wet mat 2 is formed by making rock wool into a paper, and a thermosetting resin liquid 4 is applied to the surface of the wet mat 2. The wet mat 2 is characterized in that the thermosetting resin liquid 4 is impregnated into the wet mat 2 by suction and dehydration from the back surface side of the wet mat 2.

In the present invention, the wet mat may contain a swelling agent.

[0008]

Embodiments of the present invention will be described below. FIG. 1 shows an embodiment. First, wet wool 2 is formed by wet-making the rock wool in the rock wool slurry prepared by mixing rock wool and water with a round-net papermaking machine 1. The moisture content of the wet mat 2 after papermaking can be set to 60 to 200% by weight. If the water content of the wet mat 2 is less than 60% by weight, a predetermined thickness as a rock wool board (thickness necessary to secure strength when used as a building material etc.) cannot be obtained, and When the water content of the wet mat 2 exceeds 200% by weight, the water content of the wet mat 2 is too large to obtain the strength of the wet mat 2, and in any case, the production of rock wool board is difficult and not realistic. .

Next, the wet mat 2 is conveyed to the upper side of the vacuum box 3 by the papermaking belt 5, and the inside of the vacuum box 3 is decompressed by the vacuum pump 15 connected to the vacuum box 3, so that the wet mat 2 is backside. While being sucked and dehydrated, the thermosetting resin liquid 4 is applied to the surface of the wet mat 2 by overflowing from the overflow coater 6. The thermosetting resin solution 4 is supplied to the overflow coater 6 by the supply pump 30.

By applying the thermosetting resin liquid 4 to the surface of the wet mat 2 while sucking and dehydrating from the back surface of the wet mat 2 as described above, the moisture contained in the wet mat 2 is removed from the back surface of the wet mat 2. The thermosetting resin liquid 4 applied to the surface of the wet mat 2 while being removed from the side is sucked by the vacuum pump 15 to remove the wet mat 2
The thermosetting resin liquid 4 can be impregnated into the wet mat 2. Therefore, the wet mat 2 can be uniformly impregnated with the thermosetting resin. In other words, the wet mat 2 after papermaking has a water content of 60 to 200% by weight, and the wet mat 2 having such a high water content exceeds the liquid amount that can retain water. Does not impregnate when applied. However, when the thermosetting resin liquid 4 is applied to the surface of the wet mat 2 while sucking and dehydrating from the back surface side of the wet mat 2 as described above, the moisture impregnated in the wet mat 2 becomes the thermosetting resin liquid 4. Therefore, the wet mat 2 can be uniformly replaced with the thermosetting resin.

As the thermosetting resin liquid 4, an aqueous solution in which a phenol resin or a melamine resin or a mixture of a phenol resin and a melamine resin is dissolved in water and the concentration is set to 1 to 55% by weight can be used. When the concentration of the thermosetting resin liquid 4 is less than 1% by weight, the amount of the thermosetting resin impregnated in the wet mat 2 is small and the significance of impregnating the rock wool board with the thermosetting resin is lost. If the concentration of the thermosetting resin liquid 4 exceeds 55% by weight, the concentration becomes higher than that of the undiluted solution, and the viscosity is too high to apply, which is not realistic.

When the wet mat 2 has a water content of 100% by weight (standard wet mat 2 water content), the thermosetting resin liquid 4 is applied to the water content (retained water content). It is preferably 60 to 200% by weight.
In this method, a 50% by weight thermosetting resin liquid 4 is applied to a wet mat 2 having a water content of 100% by weight based on the water content of the wet mat 2, and the degree of vacuum during suction dehydration is set to 500 m.
This is because the uniform impregnation of the thermosetting resin into the wet mat 2 tends to slightly decrease when the pressure is set to mHg.

Therefore, the wet mat 2 having a water content of 100% by weight has a water content of 60 relative to the wet mat 2.
% Of the thermosetting resin liquid 4 is applied, and the degree of vacuum at the time of suction dehydration is set to 400 mmHg, or the wet mat 2 having a water content of 100% by weight has a water content of 80% by weight with respect to the water content of the wet mat 2. Apply the thermosetting resin liquid 4,
The degree of vacuum at the time of suction dehydration is set to 200 mmHg, or the thermosetting resin liquid 4 of 100% by weight with respect to the moisture content of the wet mat 2 is applied to the wet mat 2 having a water content of 100% by weight. Vacuum degree of 100mmH
g or a water content of 100% by weight of the wet mat 2 with respect to the water content of the wet mat 2.
0% by weight of the thermosetting resin liquid 4 is applied, and the degree of vacuum at the time of suction dehydration is set to 80 mmHg, or 200% by weight based on the water content of the wet mat 2 having a moisture content of 100% by weight. Is applied and the degree of vacuum during suction dehydration is set to 60 mmHg,
It is preferable that uniform impregnation of the thermosetting resin into the wet mat 2 does not decrease.

The water content of the wet mat 2 after suction dehydration can be set to 60 to 200% by weight. If the moisture content of the wet mat 2 is less than 60% by weight, a predetermined thickness as a rock wool board (thickness necessary for securing strength or the like when used as a building material) cannot be obtained, and Water content of wet mat 2 is 2
If the content exceeds 00% by weight, the moisture contained in the wet mat 2 is too large and the strength of the wet mat 2 cannot be obtained, and in any case, it is difficult to manufacture a rock wool board, which is not practical.

The vacuum degree during the above-mentioned suction dehydration is 60 to 7
It can be set to 60 mmHg. The degree of vacuum is 60m
If it is less than mHg, the suction force becomes insufficient, and it takes too much time to dehydrate the water contained in the wet mat 2 and impregnate it with the thermosetting resin liquid 4. Further, the degree of vacuum of 760 mmHg is absolutely 0 atm, and it cannot be any higher. In addition to applying the thermosetting resin liquid 4 to the wet mat 2, an overflow coater 6 as shown in FIG.
The flow coater 16 as shown in (b), or spraying by spraying or coating by a roll coater can be adopted.

Then, the wet mat 2 impregnated with the thermosetting resin is introduced into the dryer 20, and the wet mat 2 is heated and dried at a temperature of 160 to 200 ° C. for 30 to 120 minutes and is included in the wet mat 2. The rock wool board of the present invention can be formed by curing the thermosetting resin. In the above-described embodiment of the present invention, the moisture contained in the wet mat 2 is removed by applying the thermosetting resin liquid 4 to the surface of the wet mat 2 while suction-dewatering from the back side of the wet mat 2. The thermosetting resin liquid 4 applied to the surface of the wet mat 2 while being removed from the back side of the wet mat 2 can be sucked by the vacuum pump 15 to impregnate the wet mat 2 with the thermosetting resin liquid 4. Further, the wet mat 2 can be uniformly impregnated with the thermosetting resin liquid 4. Therefore, the rock wool board formed from the wet mat 2 is uniformly impregnated with the thermosetting resin, so that it is possible to reduce the dimensional change rate of the rock wool board when absorbing water and to improve the water resistance. The strength can be improved.

In the above-described embodiment, the water content of the wet mat 2 is increased by heating the wet mat 2 impregnated with the thermosetting resin evenly to cure the thermosetting resin. The thermosetting resin may also move to the front and back surfaces of the wet mat 2 as it moves to the back surface side, which may impair the uniformity of the thermosetting resin in the wet mat 2. .

Therefore, in the invention of claim 2, the wet mat 2 containing a swelling agent is used. As a method of incorporating the swelling agent into the wet mat 2, there is a method of blending the swelling agent into rock wool slurry and forming the swelling agent together with the rock wool to form the wet mat 2. Another method of incorporating the swelling agent into the wet mat 2 is a method of incorporating the swelling agent into the thermosetting resin liquid 4 applied to the wet mat 2.

By impregnating the wet mat 2 with the swelling agent in this manner, the thermosetting resin can be captured by the swelling agent, and the swelling agent can slow the movement of water. Mat 2
It is possible to make it difficult for the thermosetting resin to move together to the front and back surfaces of the wet mat 2 as the water in the wet mat 2 moves to the front and back surfaces. Can be prevented from being impaired.

Examples of the swelling agent include starch, polyvinyl alcohol, lithium silicate and the like. Further, the compounding amount of the swelling agent can be set to 1 to 6% by weight based on the total solid content. If the content of the swelling agent is less than 1% by weight based on the total solid content, the movement of the thermosetting resin cannot be suppressed, and the content of the swelling agent is 6% by weight based on the total solid content. If it exceeds, the cost will increase.

The wet mat 2 containing a swelling agent
In the rock wool board formed by using, the variation of impregnation of the thermosetting resin in the thickness direction is 1 to 2%. As shown in FIG. 3, the variation in impregnation of the thermosetting resin is such that the rock wool board A is equally divided into three in the thickness direction (shown by an imaginary line) to form the sample pieces B, and the burning of each sample piece B is also burned. The weight loss is measured and indicated by the difference in the measured values (expressed in percentage) of the loss on ignition of each sample piece B.

[0022]

EXAMPLES The present invention will be described in detail below with reference to examples. (Example 1) Rock wool was formed into a wet mat 2 having a water content of 100% by weight.
Was sucked and dehydrated from the back side at a vacuum degree of 100 mmHg, and the phenol resin solution 4 having a concentration of 10% by weight was applied to the surface of the wet mat 2 with an overflow coater 6 to impregnate the wet mat 2 with the phenol resin. The coating amount of the phenol resin solution 4 was set to 100% by weight based on the water content of the wet mat 2. Next, wet mat 2 1
It was heated at a temperature of 80 ° C. for 75 minutes to dry the wet mat 2 and cure the phenol resin impregnated in the wet mat 2 to prepare a rock wool board.

Comparative Example 1 Rockwool was formed into a wet mat 2 having a water content of 100% by weight, and the wet mat 2 was sucked and dehydrated from the back side at a vacuum degree of 100 mmHg. It was dried to make a rock wool board. (Comparative Example 2) Wet mat 2 having a water content of 100% by weight was formed by making rock wool into paper.
Was sucked and dehydrated from the back side at a vacuum degree of 100 mmHg, and then the wet mat 2 was dried to prepare a dry rock wool plate. Next, a phenol resin solution 4 having a concentration of 10% by weight was applied to the surface of the dry rock wool plate with an overflow coater 6 to impregnate the dry rock wool plate with the phenol resin. The coating amount of the phenol resin solution 4 was set to the same amount as in Example 1 above. Next, the dry rock wool board was heated at a temperature of 180 ° C. for 75 minutes to dry the dry rock wool board and cure the phenol resin impregnated in the dry rock wool board to prepare a rock wool board.

The dimensional change rate at the time of absorbing water was measured for Example 1 and Comparative Examples 1 and 2 described above. The dimensional change rate when absorbing water is
From Example 1 and Comparative Examples 1 and 2, a sample 25 having a size of 200 mm × 30 mm (size in an air-dried state) was prepared, and the sample 25 was immersed in water at 25 ° C. for 24 hours, and then the sample of FIG.
As shown in (a) and (b), one end of the sample 25 in the short direction is brought into contact with the reference point 21, and the other end of the sample 25 in the short direction is brought into contact with the needle 22a of the dial gauge 22 to wet it. The dimensional change in the lateral direction of the sample 25 in the state is measured, and this measured value is divided by the lateral length (200 mm) in the air-dried state,
It was multiplied by 100 and expressed.

Regarding Example 1 and Comparative Examples 1 and 2 described above, the water absorption rate after immersion in warm water at 60 ° C. for 24 hours and 2
The water absorption rate after each immersion in water at 5 ° C. for 24 hours was measured. The water absorption is shown by the weight of water absorbed by the rock wool board with respect to the weight of the rock wool board of Example 1 and Comparative Examples 1 and 2. Furthermore, regarding Example 1 and Comparative Examples 1 and 2 above, the bending strength in the air-dried state was 6
The flexural strength in a wet state after being immersed in warm water of 0 ° C. for 24 hours was measured. This test is based on JIS A
It was carried out on a No. 5 test body of 1408.

[0026]

[Table 1]

As can be seen from Table 1, Example 1 in which the wet mat 2 was impregnated with the phenolic resin had a smaller dimensional change rate and higher dimensional stability than Comparative Examples 1 and 2. In addition, in Example 1, the dimensional change rate (0.
15%) and dimensional change rate of type II plywood (0.21%)
The dimensional change rate when absorbing water is small and the dimensional stability is high. Furthermore, Example 1 had a larger bending strength in the air-dried state and higher bending strength (water resistance) in the wet state than Comparative Examples 1 and 2.

(Example 2) Rock wool and other materials (inorganic fibers such as sepiolite and attapulgite, organic fibers such as pulp, and aggregates such as microsilica, silica sand, aluminum hydroxide, perlite, and shirasu balloon) A rock wool slurry containing water is formed into a paper to form a wet mat 2 having a water content of 100% by weight, and the wet mat 2 is sucked and dehydrated from the back side at a vacuum degree of 100 mmHg while the surface of the wet mat 2 has a concentration of 10% by weight. % Of the phenol resin solution 4 was applied with the overflow coater 6 to impregnate the wet mat 2 with the phenol resin. The coating amount of the phenol resin solution 4 was set to 100% by weight based on the water content of the wet mat 2. Next, the wet mat 2 is heated at a temperature of 180 ° C. for 75 minutes to dry the wet mat 2 and cure the phenol resin impregnated in the wet mat 2 so that the blending amount (unit:% by weight) of each material is A rock wool board having the structure shown in Table 2 was prepared.

(Examples 3 to 8) Rock wool and other materials (inorganic fibers such as sepiolite and attapulgite, organic fibers such as pulp, and aggregates such as microsilica, silica sand, aluminum hydroxide, perlite, and shirasu balloons) ) And a swelling agent (starch or polyvinyl alcohol (PVA) or lithium silicate (LiSiO ₂ ) and water are made into paper and a water content of 100 is obtained.
The wet mat 2 of weight% is formed, and while the wet mat 2 is sucked and dehydrated from the back side at a vacuum degree of 100 mmHg, the surface of the wet mat 2 is coated with the phenol resin solution 4 having a concentration of 10% by weight with the overflow coater 6. ,
Wet mat 2 was impregnated with phenolic resin. The coating amount of the phenol resin solution 4 was set to 100% by weight based on the water content of the wet mat 2. Next wet mat 2
Is heated at a temperature of 180 ° C. for 75 minutes to dry the wet mat 2 and cure the phenol resin impregnated in the wet mat 2, and the blending amount of each material (unit is% by weight) is shown in Table 2. I made a rockwool board that became.

Regarding Examples 2 to 8 above, the uniformity of the impregnation of the phenol resin was evaluated by the method for measuring the degree of dispersion of the impregnation of the resin described above. Table 2 shows the results.

[0031]

[Table 2]

As shown in Table 2, Examples 3 to 8 containing a swelling agent of starch, polyvinyl alcohol or lithium silicate have higher uniformity of impregnation with the phenol resin than Example 2 containing no swelling agent.

[0033]

As described above, the invention according to claim 1 of the present invention forms a wet mat by making rock wool into a paper, and a thermosetting resin liquid is applied to the surface of the wet mat.
Since the wet mat is impregnated with the thermosetting resin liquid by suction dehydration from the back side of the wet mat, the thermosetting resin in the thermosetting resin liquid applied to the surface of the wet mat is evenly applied to the wet mat. It can be impregnated, so that there is no part of the rockwool board that is not impregnated with the thermosetting resin, the water absorption rate of the rockwool board is reduced, and the entire rockwool board can be reinforced with the thermosetting resin. It is possible to obtain a rockwool board having a small dimensional change with time and having high water resistance.

In the invention according to claim 2 of the present invention, since the swelling agent is contained in the wet mat, the thermosetting resin impregnated in the wet mat can be captured by the swelling agent and the swelling agent is added. The movement of moisture can be slowed down, and as the moisture in the wet mat moves to the front and back sides of the wet mat, it also makes it difficult for the thermosetting resin to move together to the front and back sides of the wet mat. It is possible to prevent the uniformity of the thermosetting resin in the wet mat from being impaired. Therefore, the thermosetting resin of the rock wool board is uniformly impregnated, the water absorption rate of the rock wool board is reduced, and the entire rock wool board can be reinforced with the thermosetting resin. It is possible to obtain a rockwool board having a small change and a high water resistance.

[Brief description of drawings]

FIG. 1 is a schematic sectional view showing one embodiment of the present invention.

FIG. 2A is a sectional view showing the overflow coater of the above, and FIG. 2B is a front view showing the flow coater of the same.

FIG. 3 is a schematic view showing how to divide the rock wool board in the test method for examining the degree of impregnation of the thermosetting resin into the rock wool board.

FIG. 4 (a) is a schematic plan view showing a test method for examining the dimensional change of the rockwool board of the above, and FIG. 4 (b) is a side schematic view of the same.

[Explanation of symbols]

 2 Wet mat 4 Thermosetting resin liquid

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yasunori Yamaguchi 1048, Kadoma, Kadoma City, Osaka Prefecture Matsushita Electric Works Co., Ltd.

Claims (2)

[Claims] 1. A wet mat is formed by forming rock wool into a wet mat, applying a thermosetting resin solution to the surface of a wet mat, and suction-dehydrating from the back side of the wet mat. A method for producing a rock wool board, which comprises impregnating the rock wool board. 2. The method for producing rock wool board according to claim 1, wherein the wet mat contains a swelling agent.