JP3836364B2

JP3836364B2 - Method for producing coated inorganic heat insulating mat and coated inorganic heat insulating mat

Info

Publication number: JP3836364B2
Application number: JP2001384741A
Authority: JP
Inventors: 慶二大滝; 直行古田; 渡辺　　純一
Original assignee: パラマウント硝子工業株式会社
Priority date: 2001-12-18
Filing date: 2001-12-18
Publication date: 2006-10-25
Anticipated expiration: 2021-12-18
Also published as: JP2003181963A

Description

【０００１】
【発明の属する技術分野】
本発明は、建築等に用いられる無機質繊維の集合体よりなる直方体状の成形物たる無機質断熱マットの製造方法の改良および同製造方法で製造される改良された無機質断熱マットに関する。
【０００２】
【従来の技術】
無機質繊維製の直方体状の断熱マットが、外被材で、上下両面、左右両側面および前後両端のいずれの全表面を被覆された断熱材に関しては、特開平９−１５６００３号公報および特開平６−７９８４９号公報に記載されている。
【０００３】
前述の両公報の先行技術を含め、無機質繊維製のマットは、グラスウール等の無機質繊維にフェノール樹脂等の熱硬化性樹脂を塗布後、マットの無機質繊維の繊維配向方向である繊維堆積面、すなわち図１９に示すごとく、長方形状のマット４０の上面４１と下面４２と略平行する配向面４３、４３に配向されている未硬化の繊維集合体を、加熱成形して得られたものである。
【０００４】
また従来、マット密度が32kg／ｍ^３以下のマットにあっては、製品輸送コストを下げるため、その密度に応じて、規定寸法の１／２〜１／１０程度にまで輸送マットの厚さを圧縮梱包して送っているが、施工現場での開梱時、再膨張不充分で厚さが規定寸法に回復しないことがあり、施工の際の規定厚さ寸法を確保するために、圧縮前のマットの成形厚さを規定の厚さ寸法より厚くするのが一般的である。
【０００５】
しかしながら、圧縮梱包されたマットの、施工前の貯蔵期間の長短などにより、使用時に開梱包されたマットの再膨張後の厚さ寸法が予想に反し、図２１に示すごとく、規定寸法より大きくなり過ぎて、施工時にマット４０の上面４１上に施工される防湿材や、内装材が膨らんでしまうという問題があり、この解決策が望まれていた。
【０００６】
また、全表面が包装材で被覆されたマットは、家屋の壁面、屋根下面、床面等に施工されるが、図２２に示すごとく、取付面である両側部材４８、４８間の距離寸法Ｃは、現実にはバラつきがあるため、施工に手間取ったり、無理に施工することにより、マットの被覆材が破れたり、施工後に側部４８とマット４０との間に、図２２に示すごとく、隙間Ｄができるといった問題があり、その解決も望まれていた。
【０００７】
繊維の配向方向が、マットの上下面に略垂直である無機質ボードの製造法としては、特許第２８８０９３３号がある。
この方法では、無機質繊維に樹脂バインダを付与しながら堆積させて無機質繊維が平面方向とほぼ平行に配向された無機質繊維マットを形成後、該マットをその平面方向とほぼ垂直な方向に所定の幅で裁断し、該裁断物を、その裁断面が平面方向とほぼ平行となる向きにして板状に配列し、型枠内に配置後加熱成形し、無機質ボードを製造している。
しかしながら、この製造方法では、型枠内に配置する工程があるため、連続製造工程とはならず、従って、生産速度も低く、生産コストも高いという問題がある。
【０００８】
また、従来の無機質断熱マットの製造方法では、繊維化装置で繊維化後、接着剤を塗布された無機質繊維は、集綿機上で1000ｇ／ｍ^２の目付量で2200〜2250mm幅に集綿され、未硬化の無機質繊維集合体とされる。その後、乾燥機で加熱、成形された後、図２０に示すごとく、両側の耳が切除された後、縦方向に規定の幅寸法に切断し、直方体状の断熱体とされる。
次に該断熱体を既知の方法で六面パックとする。図示例は密度10kg／ｍ^３、厚さ100ｍｍ、長さ1370ｍｍの六面パック５枚採りの例であり、目付量1000ｇ／ｍ^２で、2200〜2250ｍｍ幅に集綿された繊維集合体は、左右の両耳切除後、幅2150ｍｍとされ、次いで幅430ｍｍで５列に切断される。この場合、繊維配向方向は上下面と略平行である。
【０００９】
従来の製造方法にあっては、前述の通り、生産性を上げるため集綿幅を2200〜2250と広くとっているが、
ａ幅方向の密度分布を均一にするのが困難である。
ｂ集綿機、乾燥機等が幅広のものとなるので設備費が高い。
等の問題点があった。
また乾燥効率向上策も望まれていた。
【００１０】
【発明が解決しようとする課題】
前記従来の被覆された無機質断熱材の製造方法および被覆された無機質断熱材の有する諸問題に鑑み、本発明では、従来の乾燥機での熱風通過阻害、無機質マットの輸送のための圧縮梱包後の開梱、施工時のマットの再膨張の厚さの規定寸法に対する過不足の発生、施工時の過膨張によるマットの被覆材の破れや、上面に施工される防湿材や内装材の膨らみによる施工不良発生、また従来の繊維の配向方向がマットの上下面に略垂直である無機質ボードの製造方法における低生産性、高生産コスト、従来の無機断熱マットの生産性向上に伴う品質低下、設備費増といった諸問題を解決しうるところの、繊維の配向方向がマットの上下面に略垂直である無機質ボードの高生産性、低生産コスト、品質の均一化を保有する無機質断熱マットの連続製造方法および該方法による幅方向に圧縮梱包可能、かつ上下方向および前後方向に圧縮しない無機質断熱マットを提供することを課題としている。
【００１１】
【課題を解決するための手段】
前記課題を解決するため、請求項１の製造方法の発明では、無機質原材料を繊維化装置により繊維化する繊維化工程と、繊維化後の無機質繊維に接着剤を塗布する接着剤塗布工程と、接着剤塗布後の未硬化の繊維を平面状の堆積面上に順次落下させ層状に堆積せしめ搬送しつつ長大な集合体を形成する堆積搬送工程と、未硬化の長大な繊維堆積集合体を順次搬送しつつ所定の厚さに圧縮、加熱し、所定の厚さの乾燥断熱成形体とする圧縮乾燥工程と、搬送される長大な該乾燥断熱成形体を搬送方向に沿って所定の幅に切断し所定幅の複数の矩形断面の縦切断細長体となす縦切断工程と、複数の前記矩形断面細長断熱体を所定の間隔に互に離隔し、離隔間隔を保持しつつ搬送して行く離隔工程と、離隔された複数の前記縦切断細長断熱体をそれぞれ搬送方向と直交方向に９０°反転させつつ、かつ該断熱体のうち、次工程である集合工程において長大な断熱集合体に集合される際、該集合体の左右両外側となる前記断熱体にあっては、該断熱体の下面がそれぞれ前記集合体の左右の側面となる方向に９０°反転させつつ、引続き搬送を続行する反転工程と、所定幅、所定厚さの複数の縦切断反転細長断熱材を互の間隔を０とし所定本数宛集合し、また、押えローラにより、反転細長断熱体の反転状態を保持しつつ、所定の製品幅、製品厚の長大な断熱集合体となしつつ搬送する集合工程と、長大な前記断熱集合体を規定の製品長さの断熱体に切断後、所定の前後間隔を隔てつつ搬送する長さ切断工程と、少なくとも各断熱体上下面と被覆フィルムの断熱体接触面とのいずれか一方に接着剤を塗布する接着剤塗布工程と、各断熱体の上下両面に被覆フィルムをそれぞれ供給し、断熱体の上下面を接着被覆する上下面被覆工程と、断熱体の搬送方向の左右両側面を被覆フィルムにより接着被覆する側面被覆工程と、断熱体の搬送方向前後両端面を被覆フィルムで接着被覆し、被覆されない該フィルムを断熱体から切断分離する端面被覆・フィルム分離工程と、全表面が被覆された断熱体を梱包機に送り込む、搬送工程と、梱包機で被覆断熱体を厚さ方向および幅方向の所定の枚数だけ整列せしめ、整列断熱体を幅方向に圧縮し梱包する圧縮梱包工程とからなる構成とした。
【００１２】
請求項２の発明では、無機質原材料を繊維化装置により繊維化する繊維化工程と、繊維化後の無機質繊維に接着剤を塗布する接着剤塗布工程と、接着剤塗布後の未硬化の繊維を平面状の堆積面上に順次落下させて層状に堆積せしめ搬送しつつ長大な集合体を形成する堆積搬送工程と、未硬化の長大な繊維堆積集合体を所定の厚さに加圧規正し、次いで搬送方向に沿って所定の幅に切断し、所定幅の複数の矩形断面の縦切断細長断熱体となす縦切断工程と、複数の矩形断面細長断熱体を所定の間隔に互に離隔し、離隔間隔を保持しつつ搬送して行く離隔工程と、離隔された複数の前記矩形断面縦切断細長断熱体を、それぞれ搬送方向と直交方向に９０°反転させつつ、かつ該断熱体のうち次工程である集合工程において長大な繊維集合体に集合される際、該集合体の左右両外側となる前記断熱体にあっては、該断熱体の下面を前記集合体の左右の側面となる方向に９０°反転させつつ、引続き搬送を続行する反転工程と、所定幅、所定厚さの複数の矩形断面細長断熱体を、その隣り合う側面が互に接触するように集合し、未硬化の長大な繊維集合体とする集合工程と、該繊維集合体を搬送加熱し所定の厚さに乾燥成形し、連続マットとする連続マット乾燥形成工程と、該連続マットを搬送方向に沿って規定の製品幅に、縦切断し、複数の縦切断連続マットを互に所定の間隔に離間保持しつつ搬送して行く幅切断工程と、規定幅切断連続マットを規定の製品長の断熱体に切断後所定の前後間隔を隔てつつ搬送する長さ切断工程と、少なくとも各断熱体上下面と、被覆フィルムの断熱体接触面とのいずれか一方に接着剤を塗布する接着剤塗布工程と、各断熱体の上下両面に被覆フィルムをそれぞれ供給し、断熱体の上下面を接着被覆する上下面被覆工程と、断熱体の搬送方向の左右両側面を被覆フィルムにより接着被覆する側面被覆工程と、断熱体の搬送方向前後両端面を被覆フィルムで接着被覆し、被覆されない該フィルムを断熱体から切断分離する端面被覆・フィルム分離工程と、全表面が被覆された断熱体を梱包機に送り込む搬送工程と、梱包機で被覆断熱体を厚さ方向および幅方向に所定の枚数だけ整列せしめ、整列断熱体を幅方向に圧縮し梱包する圧縮梱包工程とからなる構成とした。
【００１３】
請求項３の発明では、無機質繊維の集合体よりなる直方体状の幅、長さを有する成形物たる無機質断熱マットにおいて、該マットが矩形断面の縦切断細長断熱体の９０°反転されて集合された断熱集合体よりなり、無機質繊維の繊維配向方向である繊維堆積時の繊維方向が、前記マットの両側面と平行する方向に配向され、従って前記マットの上下両面および両端面と略垂直な方向に配向され、かつ前記マットの両側面が、前記縦切断細長断熱体の下面により形成され、更に前記マットを構成する各繊維が熱硬化樹脂で互に接着され、直方体状の全表面を被覆材で被覆されている、上記方法により製造された無機質断熱マットと言う構成とした。
【００１４】
請求項４の発明では、密度が7kg／ｍ^３〜32kg／ｍ^３であるという構成を請求項３の発明に付加した。
【００１５】
請求項５の発明では、梱包時に圧縮梱包される無機質断熱マットが幅方向のみ圧縮可能であるという構成を請求項３または請求項４の発明に付加した。
【００１６】
請求項６の発明では、直方体状の成形物である無機質断熱マットの成形厚さ寸法および成形長さ寸法が、幅方向への圧縮梱包時および施工時いかんに拘らず、規定の厚さ寸法および長さ寸法と実際的に等しいという構成を請求項３、請求項４または請求項５の発明に付加した。
【００１７】
請求項７の発明では、無機質断熱マットの各表面が、圧縮梱包の前後および施工時いかんに拘らず、被覆材で被覆されているという構成を請求項３、請求項４、請求項５または請求項６の発明に付加した。
【００１８】
請求項８の発明では、断熱集合体が、矩形断面の縦切断細長断熱体を９０°反転させて得られた縦切断反転細長断熱体を、少なくとも２本、前記断熱集合体の側面方向に並列して集合させて形成され、かつ前記縦切断細長断熱体の幅寸法Ｘと高さ寸法Ｙとの比の値が、Ｘ：Ｙ＝１：0.65ないし１：4.4の範囲内にあるという構成を請求項３、請求項４、請求項５、請求項６または請求項７の発明に付加した。
【００１９】
【発明の実施の形態】
図１は、請求項１の発明を適用した実施の一例を示しており、図２５に各工程線図を示す。繊維化工程は、無機質原料を繊維化装置１で繊維化する工程である。
【００２０】
接着剤塗布工程は、繊維化後の無機質繊維２に、接着剤スプレー３により、接着剤塗布をする工程である。
【００２１】
堆積搬送工程は、図１、図２７に示すごとく、接着剤塗布後の未硬化の繊維２を集綿機４の平面状の堆積面５上に順次落下させ層状に吸引堆積せしめ、搬送機６により搬送しつつ長大な集合体７を形成する工程である。吸引は吸引室４７でＳ方向に吸引される。
【００２２】
尚前述の繊維化工程、接着剤塗布工程、堆積搬送工程の連続工程により未硬化の長大な繊維堆積集合体を次の工程に引続いて搬送して行く工程に代え繊維化工程、接着剤工程および堆積搬送工程により得られた未硬化の長大な繊維堆積集合体をロール状に巻取っておき、前述のロール状に巻取られた長大な繊維堆積集合体のマットを、次工程に供給して行く工程とすることも出来る。
【００２３】
圧縮乾燥工程は、図２８に示すごとく、未硬化の長大な繊維堆積集合体７を、順次乾燥機８に搬送しつつ、該乾燥機８内で所定の厚さに圧縮、加熱し、所定の厚さの乾燥断熱成形体９とする工程である。
【００２４】
縦切断工程は、搬送される長大な乾燥断熱成形体９を、縦カッター１０で、搬送方向に沿って所定の幅に切断し、図３に示すごとく、所定幅の複数の矩形断面の縦切断細長断熱体１１、１１とする工程である。前記矩形断面形状を図４のＡ−Ａ断面で示す。Ａ−Ａ断面における縦切断細長断熱体１１の繊維配向方向Ｆは、集合体７、乾燥断熱成形体９と変らず水平方向である。
【００２５】
離隔工程は、複数の矩形断面細長断熱体１１、１１を、拡幅機１２で所定の間隔に互に離隔し、離隔間隔を保持しつつ搬送して行く工程である。
【００２６】
反転工程は、離隔された複数の縦切断細長断熱体１１、１１を、それぞれ、図３に示すごとく、反転部１３で搬送方向と直交方向に９０°反転させ、かつ該断熱体１１、１１のうち、次工程である集合工程において長大な断熱集合体１６に集合される際、該集合体１６の左右の側面となる前記断熱体１１、１１にあっては、図４および図５に示すごとく、該断熱体１１の下面４５が前記集合体１６の左右の側面となる方向に９０°反転させつつ、引続き搬送を続行する工程である。反転後の各縦切断反転細長断熱体１４、１４の繊維配向方向Ｇは、図５に示すごとく、搬送方向であってかつ垂直方向であり、この工程以後繊維配向方向は垂直方向に保持される。反転前の縦切断細長断熱体１１の幅と厚さとは、それぞれ反転後の縦切断反転細長体１４の厚さと幅とになる。また図１２に示すごとく、断熱体１９の左右両側は、堆積面である前記下面４５が該当することとなり、耐圧強度が増大する。
【００２７】
集合工程は、所定幅、所定厚さの複数の縦切断反転細長断熱体１４、１４を、図３に示すごとく、集合機１５で、互の間隔を０とし、所定本数宛集合し、所定の製品幅、製品厚の長大な断熱集合体１６、１６となしつつ搬送する工程である。尚図１１、図１２には、断熱集合体１６は、縦切断反転細長断熱体１４を、２本宛堆積面５側である下面４５を外側に反転し、集合する例が示されているが、所定の断熱体１９の製品幅によっては、図２４に示すごとく、もっと多数本の縦切断反転細長断熱体１４を集合せしめる場合もある。また、押えローラ１７は、前記反転細長断熱体１４の反転状態を保持する為に役立つ。
【００２８】
尚、前述の縦切断工程に続いて、拡幅機１２の直前に各縦切断細長断熱体１１、１１の上面４４に接着剤スプレー３９により接着剤を散布することにより、離隔工程、反転工程、集合工程により得られた長大な断熱集合体１６は、図１２に示すごとく、縦切断細長断熱体１１、１１の接着剤を散布された上面４４、４４同士が当接されることとなり、縦切断反転細長断熱体１４、１４の当接面４６での相互の接着がより確実となり、確実に一体化された断熱集合体１６が形成される。
【００２９】
長さ切断工程は、長大な断熱集合体１６を、長さ切断機１８において、規定の製品長さの断熱体１９、１９に切断後、搬送し、ストッパ２０により、断熱体１９、１９の前後間隔を調節する工程である。
【００３０】
以下の工程は図１に続く図２に示す機器例により説明する。接着剤塗布工程は、少なくとも各断熱体１９の上下面と被覆フィルム２１、２１の断熱体接触面とのいずれか一方に、接着剤スプレー２２により、接着剤を塗布する工程である。なお図２には、上下の被覆フィルム２１、２１に接着剤を塗布する接着剤スプレー２２、２２の実施例が示されているが、接着剤塗布装置も、塗布位置も、図示例に限られないことは勿論である。
【００３１】
上下面被覆工程は、図１２、図１３に示すごとく、各断熱体１９の上下両面に被覆フィルム２１、２１をそれぞれ供給し、上下シール機２３において、断熱体１９の上下面を接着被覆する工程である。
【００３２】
側面被覆工程は、断熱体１９の搬送方向の左右両側面を、両側シール機２４において被覆フィルム２１により接着被覆する工程である。
【００３３】
端面被覆・フィルム分離工程は、前後端シール機２５において、
断熱体１９の搬送方向前後端面を、被覆フィルム２１で接着被覆し、被覆されない該フィルム２１を断熱体１９から切断分離する工程である。
【００３４】
尚、シール機の構成は前述の構成に限られず一体シールその他のシール手段が使用可能であることは勿論である。図１２に、上下面および左右両側面を接着被覆された断熱体１９の実施の１例を、搬送方向と直角方向の断面図で示し、図１３に、更に、断熱体１９の前後両端を被覆する実施の一例を斜視図で示す。図１２においては、断熱体１９が２本の反転細長断熱体１４、１４により形成されている実施例を示し、また繊維の配向方向が断熱体１９の上下面と垂直方向であり、断熱集合体１６（断熱体１９）の左右両側面は、縦切断細長断熱体１１、１１の下面４５、４５で形成されていることを示す。
【００３５】
搬送工程は、全表面を被覆された被覆断熱体２７を、搬送装置２６、２６により、梱包機２８に送り込む工程である。次の圧縮梱包工程は、梱包機２８で被覆断熱体２７を、図６に示すごとく、厚さ方向および幅方向に所定の枚数だけ整列せしめ、整列断熱体２９を図７に示すごとく、幅方向に圧縮し、幅方向圧縮整列断熱体３０を梱包する工程である。圧縮により被覆フィルム２１の破損は全く生じない。
【００３６】
整列断熱体２９を幅方向のみに圧縮するのは、個々の断熱体１９に、長さ方向と厚さ方向との平行方向に形成されている硬化された多数の繊維配向面４３の存在により、特に集綿機４の堆積綿５に近接して形成された密度の高い繊維配向面４３および下面４２が、断熱体１９の両側に存在することにより、断熱体１９の長さ方向と厚さ方向とへの圧縮が困難であることにもよる。
【００３７】
図８〜図１１に、請求項１の発明により形成される無機質断熱マットの実施の一例を、搬送方向と垂直断面の断面図により示す。
【００３８】
図８に、乾燥機８後の乾燥断熱成形体９の一例を示す。図８は、両側面の耳切除後の1000ｍｍ幅の該成形体９の部分平面図である。目付量は2150ｇ／ｍ^２とする。
【００３９】
図９は前記乾燥断面成形体９の垂直断面図である。繊維配合面４３の配向方向は水平方向であり、厚さは225ｍｍに成形されている。下面４５は、繊維密度が高い。
【００４０】
図１０に、縦カッタ１０により縦切断された縦切断細長断熱体１１、１１を示す。縦切断幅は100ｍｍであり幅1000ｍｍの乾燥断熱成形体９は、１０本縦切断細長断熱体１１、１１に縦切断されている。この位置での該断熱体１１の厚さは、225ｍｍであり、繊維配向方向は水平である。
【００４１】
図１１は、集合機１５後の断熱集合体１６、１６を示す。図示例では、各断熱集合体１６は２本の縦切断反転細長断熱体１４、１４により形成されている。
この位置での繊維配向方向は垂直方向に９０°反転されている。
各断熱集合体１６は、幅は225×２＝450ｍｍ、厚さは100ｍｍとなる。
【００４２】
従って図８〜図１１に示す実施例では、繊維化後接着剤を塗布された無機質繊維２は2150ｇ／ｍ^２の目付量で1050〜1100ｍｍ幅に集綿され未硬化の繊維集合体７とされる。次いで該集合体７は、乾燥機８で成形厚さ225ｍｍに加熱、成形された後、両側の耳を切除され、1000ｍｍ幅とされ、更に100ｍｍ幅に縦切断され、100ｍｍ幅の１０本の連続した矩形断面の帯状物である縦切断細長断熱体１１、１１とされる。
次に個々の該断熱体１１、１１は、下面４５、４５がそれぞれ、図１１に示すごとく、断熱集合体１６の両側面となる様に搬送方向に対し、互に逆に９０°方向へ反転され、２本宛集合され、断面寸法が、厚さ100ｍｍ、幅450ｍｍの５本の連続した矩形断面の帯状物である断熱集合体１６、１６とされる。
次に該断熱集合体１６は長さ切断機１８により規定寸法長さ1370ｍｍに切断され、断熱体１９とされ、各断熱体１９、１９は所定の間隔をおいて搬送され既知の手段により六面被覆される。
【００４３】
図１４は、請求項２の発明を適用した実施の一例を示し、図２６に各工程線図を示す。
本発明では、繊維化工程、接着剤塗布工程、堆積搬送工程までの各工程は請求項１の発明と同じであるので説明は省略する。
尚、以下同一対象は同一番号とする。
【００４４】
次の縦切断工程は、未硬化の長大な繊維堆積集合体７を、搬送機３２により搬送しながら、押えローラ３１により所定の厚さに加圧規正し、次いで縦カッタ１０により、搬送方向に沿って所定の幅に縦切断し、所定幅の複数の矩形断面の未硬化の縦切断細長断熱体３３となす工程である。
【００４５】
離隔工程は、複数の前記矩形断面細長断熱体３３を、拡幅機１２により、所定の間隔に互に離隔し、離隔間隔を保持しつつ搬送して行く工程である。
【００４６】
次に反転工程となる。該工程は、離隔された複数の矩形断面細長断熱体３３を、搬送しつつ、それぞれ搬送方向と直交方向に９０°反転させつつ、かつ該断熱体３３のうち次工程である集合工程において長大な繊維集合体３５に集合される際、該集合体３５の左右両外側となる前記断熱体３３にあっては、該断熱体３３の下面を、図１１に示すと同様に、前記集合体３５の左右の側面となる方向に９０°反転させつつ、引続き搬送を続行する工程である。
【００４７】
集合工程は、所定幅、所定厚さの複数の未硬化の縦切断矩形断面反転細長断熱体３４を、集合機１５において、その隣り合う側面が互に接触するように集合し、未硬化の長大な単一の繊維集合体３５とする工程である。
【００４８】
連続マット乾燥形成工程は、乾燥機８において前記繊維集合体３５を搬送加熱し、所定の厚さに乾燥成形し、単一の連続マット３６とする工程である。
【００４９】
幅切断工程は、縦カッタ３７により、前記連続マット３６を搬送方向に沿って規定の製品幅に縦切断し、複数の縦切断連続マット３８とし、該マット３８を互に所定の間隔に離隔保持しつつ搬送して行く工程である。
【００５０】
次に長さ切断工程以下の各工程は、請求項１の発明の各工程と同一であるから説明を省略する。
【００５１】
図１５は縦カッタ１０から反転部１３までの部分拡大平面図である。図示例では、集合体７が縦カッタ１０により、４本の縦切断矩形断面細長断熱体３３、３３に切断され、中間図示を省略するが、反転部１３で９０°反転され、集合機１５で集合され単一の繊維集合体３５となる様相を示す。
【００５２】
図１６は図１４および図１５中切断線Ｄ−Ｄで示す前記集合体７の進行方向直角断面図であり、繊維の配向面４３の配向方向は水平方向である。図１７は同上切断線Ｅ−Ｅで示す前記繊維集合体３５の前図同様の断面図であり、反転集合後の繊維集合体３５の繊維の配向方向は垂直方向である。
【００５３】
請求項２の発明に示す未硬化の縦切断矩形断面細長断熱体３３を９０°反転させて得られた未硬化の繊維集合体３５の、請求項１の発明の方法によるものとの比較では、
ａ請求項１の発明では未硬化の集合体７が、図２８に示すごとく、繊維の配向方向が水平のままの状態で乾燥機８に搬送されるので、乾燥機８内の乾燥用の熱風は通常下から上へ垂直方向８Ｖ方向）に流されるので、熱風は、繊維の各配向面４３と密度の高い下面４２とを通過することとなり、通過抵抗が大きく、また繊維同士が接着剤で結合され成形されていることと、上下面に表皮が形成されるので、熱伝導率が小さくなり、乾燥効率がやや劣る。この傾向は低密度製品から高密度製品のいずれかにも全般にいえる。
ｂ請求項２の発明によれば、未硬化の縦切断矩形断面細長断熱体３３を９０°反転させ、縦切断矩形断面反射細長断熱体３４となし、該断熱体３４を集合し、繊維配向方向が垂直である繊維集合体３５となした後乾燥機８に搬送し、加熱乾燥することとなり、低密度品から高密度品まで（７kg／ｍ^３〜200kg／ｍ^３）の製品製造に適する。乾燥機８内では、図１８に示すごとく、繊維配向面４３の間を乾燥熱風が通過するので、加熱乾燥時矢印Ｖの方向に下から上へ垂直方向に流れる乾燥熱風の通気抵抗が少なく、請求項１の発明に比べて、熱風の通過が良好となるので乾燥効率が良好となり、乾燥に要する通風エネルギおよび加熱エネルギが共に減少され、省エネルギ効果を増大する。
【００５４】
尚、請求項１、請求項２の両発明の製造方法によれば、特許第２８８０９３３号発明の公知の製造方法に比べて、連続生産方式であるので生産性が遥かに良好となる。
【００５５】
図１および図１６に示すごとく、集綿機４の堆積面５に接して形成される集合体７の下面４２は、その上に堆積される繊維層が、前記堆積面の下方より吸引室４７へと吸引され堆積されて行くため、下面４２に近い下方の配向面４３程密度が高くなり、請求項１の発明では、この状態のまま集合体７が乾燥機８へ搬送され、図２８に示すごとく、熱風Ｖを下から上へ通過せしめて乾燥させる場合、高密度の下面４２側および積層された配向面４３により熱風Ｖの通過が阻害されるため乾燥効率が請求項２の発明に比べてやや劣り、乾燥効率の向上および乾燥コストの低下は期待出来ない。
【００５６】
請求項８の発明での数値限定について説明する。製品となる断熱体１９の製品幅と製品厚の寸法は、
製品幅 390〜600ｍｍ
製品厚 50ｍｍ、75ｍｍ、100ｍｍ、200ｍｍ
のものが多い、従って上記寸法の製品とする。断熱体１９を構成する矩形断面の縦切断細長断熱体１１の構成数は多くない方が好ましい。
その理由は、多くなる程、生産工程が複雑化し、不安定化をもたらし、縦切断細長断熱体相互の当接面の増加による断熱体１９の熱伝導率の悪化をもたらす等の要因が増大するからである。また、図２３に示すごとく、縦切断細長断熱体１１の幅をＸ、高さをＹとすると、Ｙ寸法は余り高く出来ない。その理由は、図１に示す乾燥機６の高さを高くする必要が生じ、設備費が高くなることや、Ｙが大きくなると、９０°反転する際の反転構造が難しくなること等によるマイナス面が現れるからである。
【００５７】
以上の理由により、前述の製品幅、製品厚の製品について現有設備に対する縦切断細長断熱体１１（表中細長体と略記する）の適切な幅Ｘ、高さＹの値とＸ／Ｙの比の値、前記縦切断細長断熱体１１の９０°反転後の縦切断反転細長断熱体１４を所要本数集合せしめて得られる断熱体１９の適切な幅および厚さの値について、表１に示すごとき考案を行った。尚、断熱体１９の幅は、幅方向に圧縮可能であるゆえ必要製品幅よりやや大とすることが出来る。
【００５８】
表１

【００５９】
考察の結果、製品製造に必要とする細長体の幅Ｘおよび高さＹの種類を少なくすることが可能であること、および必要なＸ／Ｙの値が、
Ｘ／Ｙ＝１／0.65ないしＸ／Ｙ＝１／4.4
の範囲内にあれば、充分であり、前記範囲にあれば製造設備に改変を加える必要がなく、生産コストの低下をもたらすことが明らかになった。
尚、図２４に、表１中の代表例として製品厚50ｍｍ、製品幅390ｍｍのものに対し、細長体の幅Ｘ＝50ｍｍ、高さＹ＝100ｍｍ、Ｘ／Ｙ＝１／2.0で、断熱体生産する必要本数は４本であり、断熱体の幅400ｍｍ、厚さ50ｍｍである関係を示す。従って幅400ｍｍの断熱体を390ｍｍ幅に圧縮して使用するものとする。外の計算例についても同様である。
【００６０】
【発明の効果】
請求項１の発明では、
ａ繊維配向方向が、上下面と垂直方向でかつ搬送方向であるところの、被覆された無機質断熱材を、連続工程により製造することができるので、生産性が高い。
ｂ縦切断反転細長断熱体を所要幅の断熱集合体に集合形成しうるので、集綿幅の狭い、例えば1050〜1100ｍｍ幅の狭い集綿機で生産することができる。
ｃ幅の狭い集綿機上の繊維の幅方向の密度分布を均一にすることが容易となり、製品の品質向上をもたらし、また集綿機、乾燥機その他の各工程の設備が幅狭のもので充分となり設備費が安くすむ。
ｄ被覆された断熱体を被覆されたまま幅方向に圧縮して梱包ができるため、製品の損傷が少なく、製品の保管費、輸送費が安くすむ。
という各種の効果を奏する。
【００６１】
請求項２の発明では、前項に記す諸効果に加えて、乾燥機に入る前の繊維集合体の繊維配向方向を上下面と垂直方向としたことにより、乾燥機における乾燥効率およびエネルギ効率が、請求項１の発明より向上することが可能となる効果を奏する。
【００６２】
請求項３の無機断熱マットの発明では、無機質繊維の繊維配向方向が、該マットの両側面と、平行する方向に配向されているので、該マットへの前後方向および上下方向からの負荷に対し、変形抵抗性が大であり、また前記マットの両側面が、集綿機の堆積面に接する下面で形成され、該下面は、前記堆積面で、穴明きコンベア上で空気を上からしたへ吸引するために、上面に比べて、下面は密度を高くなり、繊維への接着剤の付着率も高くなり、かつ堆積面に接触する下面の表面も比較的平滑となり、下面表皮も強靭になるという特性があり、従って前記マットの側面表皮は強靭となり、側面の変形が起り難く、しかも圧縮梱包のマットの開梱後は、側面方向への膨張が容易であり、圧縮梱包により輸送、保管時にコンパクトとなるため、輸送費、保管費が低廉であり、施工時には間柱のごとき両側部材等との間に隙間を生じることなく設置可能であり、取扱が容易で断熱工事に優れた効果を奏する。
【００６３】
請求項４の発明では、従来の製造方法によれば、生産性を上げるためには製造ラインの製造幅を広幅にすることが通常行われ、そのために７kg／ｍ^３〜32kg／ｍ^３の低密度の無機断熱マットは、幅方向の密度分布を均一にするのが困難であった。また、厚さ方向に圧縮梱包されるため、施工時および施工後に既述の問題点をかかえていた。
本発明の製造方法によれば、狭幅の製造ラインでも生産性を維持し生産でき、かつ、繊維配向方向が前後方向および上下方向と平行方向にあるため、低密度でありながら、長さ方向および厚さ方向に変形し難く、輸送、保管および施工時にも、形状保持に優れた製品および密度分布の均一な製品を提供しうる効果を奏する。
【００６４】
請求項５の発明では、被覆されたマットが、被覆されたまま、幅方向にのみ圧縮可能であり、圧縮梱包により輸送、保管のコスト低下の効果を奏すると共に、開梱後被覆されたまま幅方向へのみ膨張可能であり、断熱工事施工に極めて適した製品となり得る効果を奏する。
【００６５】
請求項６の発明では、マットの厚さ寸法が幅方向への圧縮梱包の際も、施工のため梱包が外された後にも、規定の厚さ寸法と実質的に等しく、従来の厚さ方向圧縮品と異なり、施工時の厚さ方向の膨張過大や過小のトラブルがなく、該マットの上被覆施工加工に何等支障を生ずることがなく、被覆フィルムの破損を生ずることもなく、また取付面である幅方向両側部材間の距離寸法のバラツキに拘らず、膨張により部材間に隙間なく納まり、施工に手間取ることがなく、施工費の低減をもたらす効果を奏する。
【００６６】
請求項７の発明では、マットの厚さ寸法と長さ寸法が、圧縮梱包の前後および施工時いかんに拘らず変らず、被覆材の破損もなく被覆材の被覆が維持されるため、マットの品質低下を生ずることがない効果を奏する。
【００６７】
請求項８の発明では、必要とする製品寸法に対し、製造設備を改変することもなく、対処することができ、製品の製造に必要な縦切断細長断熱体の種類を減少することが可能であり、従って設備費の増大を招くことがなく、生産コストも低減でき、更に、品質の良い断熱材を安定的に生産しうるという効果を奏する。
【図面の簡単な説明】
【図１】請求項１の発明を適用した製造装置のうち、断熱体への被覆フィルムの上下シール以前までの装置の略示側面図である。
【図２】図１以降の製造装置の略示側面図である。
【図３】製造装置の部分拡大平面図である。
【図４】図３中Ａ−Ａ垂直断面図である。
【図５】図３中Ｂ−Ｂ垂直断面図である。
【図６】幅方向圧縮前の梱包状態を示す斜視図である。
【図７】幅方向圧縮後の梱包状態を示す斜視図である。
【図８】耳切除後の無機繊維集合体の部分平面図である。
【図９】図８の集合体の搬送方向垂直断面図である。
【図１０】縦切断細長断熱体の搬送方向垂直断面図である。
【図１１】縦切断反転細長断熱体を集合して得られる断熱集合体の同上垂直断面図である。
【図１２】被覆断熱体の同上垂直断面図である。
【図１３】六面被覆状態を示す被覆断熱体の斜視図である。
【図１４】請求項２の発明を適用する製造装置の被覆フィルム被覆工程以前までの装置の略示側面図である。
【図１５】製造装置の中間を省略する部分拡大平面図である。
【図１６】図１および図１５中Ｄ−Ｄ垂直断面図である。
【図１７】図１および図１５中Ｅ−Ｅ垂直断面図である。
【図１８】請求項２の発明の乾燥機内の繊維集合体の熱風通過状態を説明する搬送方向垂直断面図である。
【図１９】従来の被覆マットの長さ方向垂直断面図である。
【図２０】従来品の耳切除後、縦切断をされたマットの配列を示す説明図である。
【図２１】従来品の施工後の膨張状態を示す長さ方向垂直断面図である。
【図２２】同上施工後の隙間発生を示す垂直断面図である。
【図２３】縦切断細長断熱体の垂直方向断面図である。
【図２４】製品断面図および所要縦切断細長断熱体断面図の関係説明図である。
【図２５】請求項１の発明の工程線図である。
【図２６】請求項２の発明の工程線図である。
【図２７】集綿機の堆積面上に吸引堆積される集合体を示す搬送方向直角垂直断面図である。
【図２８】請求項１の発明の乾燥機内の集合体の熱風通過状態を説明する搬送方向直角垂直断面図である。
【符号の説明】
１繊維化装置
２無機質繊維
３接着剤スプレー
４集綿機
５堆積面
６搬送機
７集合体
８乾燥機
９乾燥断熱成形体
１０縦カッタ
１１縦切断細長断熱体
１２拡幅機
１３反転部
１４縦切断反転細長断熱体
１５集合機
１６断熱集合体
１７押えローラ
１８長さ切断機
１９断熱体
２０ストッパ
２１被覆フィルム
２２接着剤スプレー
２３上下シール機
２４両側シール機
２５前後端シール機
２６搬送装置
２７被覆断熱体
２８梱包機
２９整列断熱体
３０幅方向圧縮整列断熱体
３１押えローラ
３２搬送機
３３縦切断矩形断面細長断熱体
３４縦切断矩形断面反転細長断熱体
３５繊維集合体
３６連続マット
３７縦カッタ
３８縦切断連続マット
４３配向面
４４上面
４５下面[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an improvement of a method for manufacturing an inorganic heat insulating mat which is a rectangular parallelepiped shaped product made of an aggregate of inorganic fibers used in construction and the like, and an improved inorganic heat insulating mat manufactured by the manufacturing method.
[0002]
[Prior art]
Regarding a heat insulating material in which a rectangular parallelepiped heat insulating mat made of an inorganic fiber is covered with a covering material on all surfaces of upper and lower surfaces, left and right side surfaces, and front and rear ends, Japanese Patent Laid-Open Nos. 9-156003 and 6 -79849.
[0003]
Including the prior art of both the above-mentioned publications, the mat made of inorganic fiber is a fiber deposition surface that is the fiber orientation direction of the inorganic fiber of the mat after applying a thermosetting resin such as phenol resin to inorganic fiber such as glass wool, that is, As shown in FIG. 19, an uncured fiber assembly oriented on the

orientation surfaces

43 and 43 substantially parallel to the upper surface 41 and the lower surface 42 of the rectangular mat 40 is obtained by thermoforming.
[0004]
Conventional mat density is 32kg / m. ³ In the following mats, in order to reduce the product transportation cost, depending on the density, the thickness of the transportation mat is compressed and sent to about 1/2 to 1/10 of the specified dimension. When unpacking at the site, re-expansion is insufficient and the thickness may not recover to the specified size.In order to secure the specified thickness at the time of construction, the molding thickness of the mat before compression is the specified thickness. Generally, it is thicker than the thickness.
[0005]
However, due to the length of the storage period before construction of the mat that has been compressed and packed, the thickness dimension after re-expansion of the mat that has been unpacked at the time of use is unexpected and becomes larger than the specified dimension as shown in FIG. Therefore, there is a problem that the moisture-proof material and the interior material that are constructed on the upper surface 41 of the mat 40 at the time of construction swell, and this solution has been desired.
[0006]
Further, the mat whose entire surface is covered with the packaging material is applied to the wall surface of the house, the lower surface of the roof, the floor surface, etc. 2 As shown, the distance C between the

side members

48, 48, which are the mounting surfaces, varies in reality. There is a problem that a gap D is formed between the portion 48 and the mat 40 as shown in FIG.
[0007]
Japanese Patent No. 2880933 discloses a method for producing an inorganic board in which the fiber orientation direction is substantially perpendicular to the upper and lower surfaces of the mat.
In this method, the inorganic fiber is deposited while applying a resin binder to the inorganic fiber to form an inorganic fiber mat in which the inorganic fiber is oriented substantially parallel to the plane direction, and then the mat is formed with a predetermined width in a direction substantially perpendicular to the plane direction. The cut product is arranged in a plate shape in a direction in which the cut surface is substantially parallel to the plane direction, and is placed in a mold and heat-molded to produce an inorganic board.
However, in this manufacturing method, since there is a process of arranging in a mold, it is not a continuous manufacturing process, and therefore there is a problem that the production speed is low and the production cost is high.
[0008]
Further, in the conventional method for manufacturing an inorganic heat insulating mat, the inorganic fiber coated with an adhesive after being fiberized by a fiberizing apparatus is 1000 g / m on a cotton collecting machine. ² Is gathered to a width of 2200 to 2250 mm to form an uncured inorganic fiber aggregate. Then, after being heated and molded by a dryer, as shown in FIG. 20, the ears on both sides are cut off and then cut into a predetermined width dimension in the vertical direction to obtain a rectangular parallelepiped heat insulator.
Next, the heat insulator is formed into a six-sided pack by a known method. The example shown is density 10kg / m ³ This is an example of taking six six-sided packs with a thickness of 100 mm and a length of 1370 mm, and a basis weight of 1000 g / m ² Then, the fiber aggregates collected to a width of 2200 to 2250 mm are cut to 5150 mm in width after cutting both left and right ears, and then cut into 5 rows of 430 mm in width. In this case, the fiber orientation direction is substantially parallel to the upper and lower surfaces.
[0009]
In the conventional manufacturing method, as described above, the collection width is wide as 2200 to 2250 in order to increase productivity.
a It is difficult to make the density distribution in the width direction uniform.
b Equipment cost is high because cotton collectors and dryers are wide.
There was a problem such as.
A measure for improving the drying efficiency was also desired.
[0010]
[Problems to be solved by the invention]
In view of various problems of the conventional method for manufacturing a coated inorganic heat insulating material and the coated inorganic heat insulating material, in the present invention, after compression packing for inhibiting hot air passage in a conventional dryer and transporting the inorganic mat. Unpacking of the mat, excess or deficiency of the mat's re-expansion thickness during construction, breakage of the mat covering due to over-expansion during construction, or swelling of moisture-proof materials and interior materials applied on the top surface Occurrence of poor construction, low productivity, high production cost, quality deterioration due to improved productivity of conventional inorganic heat insulating mats, facilities in the conventional method of manufacturing an inorganic board in which the fiber orientation direction is substantially perpendicular to the upper and lower surfaces of the mat A series of inorganic heat insulating mats that can solve various problems such as increased costs, while maintaining high productivity, low production cost, and uniform quality of inorganic boards in which the fiber orientation direction is substantially perpendicular to the top and bottom surfaces of the mat It has an object to provide an inorganic insulation mat in the width direction by the production method and the method baling possible and not compressed in the vertical and longitudinal directions.
[0011]
[Means for Solving the Problems]
In order to solve the above problems, in the invention of the manufacturing method of claim 1, a fiberizing step of fiberizing an inorganic raw material with a fiberizing device, an adhesive applying step of applying an adhesive to the inorganic fiber after fiberization, A stacking and transporting process for forming a long aggregate while sequentially dropping and transporting uncured fibers after application of adhesive onto a flat stacking surface and transporting them in sequence, and an uncured and long fiber deposition aggregate Compressed and heated to a predetermined thickness while being transported to form a dry heat insulation molded body having a predetermined thickness, and the long dry heat insulation formed body to be transported is cut into a predetermined width along the transport direction. A vertical cutting step of forming a plurality of rectangular cross-sections having a predetermined width and a plurality of rectangular cross-sections, and a separation step of separating the plurality of rectangular cross-section heat insulators from each other at a predetermined interval and carrying the separation intervals And a plurality of the longitudinally cut elongated insulators separated from each other. The heat insulating body that is turned 90 ° in the direction perpendicular to the conveying direction and is assembled to a long heat insulating assembly in the next assembly step of the heat insulating body, which becomes the left and right outer sides of the assembly. In this case, a reversing step of continuing the conveyance while reversing 90 ° in the direction in which the lower surface of the heat insulating body becomes the left and right side surfaces of the assembly, and a plurality of vertical cutting reversals having a predetermined width and a predetermined thickness. Spacing long strips of insulation 0 Assembling to a predetermined number, In addition, while holding the reverse state of the reverse elongated heat insulator by the presser roller, An assembly process for transporting the product with a predetermined product width and product thickness as a long heat insulation assembly, and cutting the long heat insulation assembly into a heat insulator with a predetermined product length, and then transporting the product with a predetermined front-rear spacing. A length cutting step, an adhesive application step of applying an adhesive to at least one of the upper and lower surfaces of each heat insulator and the heat insulator contact surface of the coating film, and supplying a coating film to each of the upper and lower surfaces of each heat insulator Adhesive coating of upper and lower surfaces of the heat insulating body, side surface covering process of covering both left and right side surfaces of the heat insulating body with a covering film, and bonding both front and rear end surfaces of the heat insulating body with a covering film End coating / film separation process to cut and separate the uncoated film from the insulation, coating process, feeding the insulation coated on the entire surface to the packaging machine, and the coating insulation in the thickness direction by the packaging machine and Allowed alignment predetermined number of directions, and configured to compress aligned insulation body in the width direction comprising a bale step of packaging.
[0012]
In the invention of claim 2, a fiberizing process for fiberizing an inorganic raw material by a fiberizing device, an adhesive applying process for applying an adhesive to the inorganic fiber after fiberizing, and an uncured fiber after applying the adhesive A deposition transporting step of forming a long aggregate while dropping and transporting in a layered manner by sequentially dropping onto a flat deposition surface, and pressurizing and regulating the uncured long fiber deposition aggregate to a predetermined thickness, Next, cutting to a predetermined width along the conveying direction, a longitudinal cutting step to become a vertically cut elongated heat insulator of a plurality of rectangular cross sections of a predetermined width, and a plurality of rectangular cross sectional elongated heat insulators are separated from each other at a predetermined interval, A separation step of conveying while maintaining a separation interval, and a plurality of the separated rectangular cross-section longitudinally cut elongated heat insulators, each inverted by 90 ° in a direction orthogonal to the conveyance direction, and the next step of the heat insulators Is assembled into a long fiber assembly in the assembly process In the heat insulating body on the left and right outer sides of the assembly, the reversing step of continuing the conveyance while reversing the lower surface of the heat insulating body by 90 ° in the direction of the left and right side surfaces of the assembly. And a plurality of rectangular cross-section elongated heat insulators having a predetermined width and a predetermined thickness are assembled so that their adjacent side surfaces are in contact with each other, and an uncured long fiber assembly, and the fiber assembly A continuous mat drying and forming step to form a continuous mat by heating and conveying to a predetermined thickness, and longitudinally cutting the continuous mat to a specified product width along the conveying direction, thereby forming a plurality of longitudinally cut continuous mats. A width cutting step of transporting while maintaining a predetermined spacing apart from each other, and a length cutting step of transporting the predetermined width cutting continuous mat to a heat insulating body of a predetermined product length after a predetermined front-to-back spacing; At least the top and bottom surfaces of each insulation and the insulation of the coating film An adhesive application process for applying an adhesive to any one of the above, an upper and lower surface coating process for supplying a coating film on the upper and lower surfaces of each heat insulator, and adhesively covering the upper and lower surfaces of the heat insulator, and transportation of the heat insulator Side coating process in which both left and right sides of the direction are adhesively coated with a coating film, and both end surfaces before and after the transport direction of the heat insulating body are adhesively coated with a coating film, and the end surface coating and film separation process in which the uncoated film is cut and separated from the heat insulating body And a transporting process to send the insulation coated on the entire surface to the packing machine, and the packing machine aligns a predetermined number of coated insulations in the thickness and width directions and compresses the aligned insulation in the width direction for packing. It was set as the structure which consists of a compression packing process to do.
[0013]
In the invention of claim 3, in the inorganic heat insulating mat which is a molded product having a rectangular parallelepiped width and length made of an aggregate of inorganic fibers, the mat is assembled by inverting 90 ° of a vertically cut elongated heat insulating body having a rectangular cross section. The fiber orientation during fiber deposition, which is the fiber orientation direction of the inorganic fibers, is oriented in a direction parallel to the both side surfaces of the mat, and therefore is substantially perpendicular to the upper and lower surfaces and both end surfaces of the mat. And both sides of the mat are formed by the lower surface of the longitudinally cut elongated heat insulator, and the fibers constituting the mat are bonded to each other with a thermosetting resin so that the entire surface of the rectangular parallelepiped is covered with the covering material. Covered with The inorganic heat insulating mat manufactured by the above method The configuration.
[0014]
In the invention of claim 4, the density is 7 kg / m. ³ ~ 32kg / m ³ The configuration of the above is added to the invention of claim 3.
[0015]
In invention of Claim 5, the structure that the inorganic heat insulation mat compressed and packed at the time of packing is compressible only in the width direction was added to invention of Claim 3 or Claim 4.
[0016]
In the invention of claim 6, the molding thickness dimension and the molding length dimension of the inorganic heat-insulating mat, which is a rectangular parallelepiped molded product, are the specified thickness dimension, regardless of whether it is compressed in the width direction or during construction. The configuration of being substantially equal to the length dimension is added to the invention of

claim

3, 4 or 5.
[0017]
In the invention of claim 7, the surface of each inorganic heat insulating mat is covered with a covering material regardless of whether it is before or after compression packing and during construction. Claim 3, Claim 4, Claim 5 or Claim Added to the invention of Item 6.
[0018]
In the invention of claim 8, the heat insulation assembly is arranged in parallel with at least two longitudinally cut reversal elongated heat insulators obtained by reversing a vertically cut slender heat insulator having a rectangular cross section in a side direction of the heat insulation assembly. And the ratio of the width dimension X to the height dimension Y of the longitudinally cut elongated heat insulator is in the range of X: Y = 1: 0.65 to 1: 4.4. This is added to the invention of claim 3, claim 4, claim 5, claim 6 or claim 7.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an example to which the invention of claim 1 is applied, and FIG. 25 shows each process diagram. The fiberizing process is a process of fiberizing the inorganic raw material with the fiberizing apparatus 1.
[0020]
The adhesive application process is a process in which an adhesive is applied to the inorganic fiber 2 after fiberization by an adhesive spray 3.
[0021]
As shown in FIG. 1 and FIG. 27, the stacking and transporting step sequentially drops the uncured fibers 2 after the application of the adhesive onto the planar stacking surface 5 of the cotton collecting machine 4 and sucks and deposits them in a layered manner. This is a step of forming a long assembly 7 while being conveyed by the above process. The suction is sucked in the S direction in the suction chamber 47.
[0022]
It should be noted that the fiberizing process, adhesive process instead of the process of transporting the uncured long fiber accumulation aggregate following the next process by the continuous process of the above-mentioned fiberizing process, adhesive application process, and deposition transport process. And the uncured long fiber accumulation aggregate obtained by the deposition conveyance process is wound up in a roll shape, and the mat of the long fiber deposition aggregate wound in the roll shape is supplied to the next process. It can also be a process.
[0023]
As shown in FIG. 28, the compression drying step compresses and heats the uncured long fiber accumulation aggregate 7 to a predetermined thickness in the dryer 8 while sequentially transporting the uncured fiber accumulation aggregate 7 to the dryer 8. This is a step for forming a dry insulation molded body 9 having a thickness.
[0024]
In the longitudinal cutting step, the long dry heat-insulated molded body 9 to be transported is cut into a predetermined width along the transport direction with the vertical cutter 10, and as shown in FIG. In this process, the

elongated heat insulators

11 and 11 are formed. The rectangular cross-sectional shape is shown by the AA cross section of FIG. The fiber orientation direction F of the longitudinally cut elongated heat insulator 11 in the AA cross section is the same as the aggregate 7 and the dry heat insulation molded body 9 and is the horizontal direction.
[0025]
The separation step is a step in which the plurality of rectangular cross-section elongated

heat insulators

11 and 11 are separated from each other at a predetermined interval by the widening machine 12 and conveyed while maintaining the separation interval.
[0026]
In the reversing step, as shown in FIG. 3, each of the plurality of longitudinally cut elongated

heat insulators

11, 11 separated from each other is reversed 90 ° in the direction perpendicular to the conveying direction by the reversing unit 13. Among them, when assembled into the long heat insulation assembly 16 in the next assembly step, the

heat insulation bodies

11 and 11 which are the left and right side surfaces of the assembly 16 are as shown in FIGS. 4 and 5. In this step, the conveyance is continued while the lower surface 45 of the heat insulator 11 is turned 90 ° in the direction of the left and right side surfaces of the assembly 16. As shown in FIG. 5, the fiber orientation direction G of each longitudinally cut inverted

elongated heat insulator

14, 14 after inversion is the transport direction and the vertical direction, and the fiber orientation direction is maintained in the vertical direction after this step. . The width and thickness of the longitudinally cut elongated heat insulator 11 before inversion are the thickness and width of the longitudinally cut inverted elongated body 14 after inversion, respectively. Moreover, as shown in FIG. 12, the said lower surface 45 which is a deposition surface corresponds to the both right and left sides of the heat insulating body 19, and a pressure | voltage resistant strength increases.
[0027]
As shown in FIG. 3, the assembly process includes a plurality of longitudinally cut inverted

elongated insulators

14 and 14 having a predetermined width and a predetermined thickness. Gathering machine 15, the distance between each other 0 In this process, the assembly is performed for a predetermined number of pieces, and the

heat insulation assemblies

16 and 16 having a predetermined product width and product thickness are formed. 11 and 12 show an example in which the heat insulating assembly 16 is obtained by reversing the vertically cut reversal elongated heat insulating body 14 by reversing the lower surface 45 on the side of the two deposition surfaces 5 to the outside. Depending on the product width of the predetermined heat insulator 19, as shown in FIG. 24, a larger number of longitudinally cut and inverted elongated heat insulators 14 may be assembled. The presser roller 17 is useful for maintaining the inverted state of the inverted elongated heat insulator 14.
[0028]
In addition, following the above-described longitudinal cutting step, the separating step, the reversing step, the assembly are performed by spraying the adhesive with the adhesive spray 39 on the upper surface 44 of each longitudinally cut elongated

insulator

11, 11 immediately before the widening machine 12. As shown in FIG. 12, the long heat insulating assembly 16 obtained by the process comes into contact with the

upper surfaces

44, 44 to which the adhesive of the vertically cut

elongated heat insulators

11, 11 is spread, and the vertical cut inversion is reversed. Mutual adhesion at the contact surface 46 of the

elongated heat insulators

14 and 14 becomes more reliable, and the heat insulating assembly 16 that is reliably integrated is formed.
[0029]
In the length cutting step, the long heat insulating assembly 16 is cut into the

heat insulating bodies

19 and 19 having a specified product length by the length cutting machine 18 and then transported, and before and after the

heat insulating bodies

19 and 19 by the stopper 20. This is a step of adjusting the interval.
[0030]
The following steps will be described with reference to the device example shown in FIG. 2 following FIG. The adhesive application step is a step of applying an adhesive by an adhesive spray 22 to at least one of the upper and lower surfaces of each heat insulator 19 and the heat insulator contact surfaces of the

coating films

21 and 21. FIG. 2 shows an embodiment of the

adhesive sprays

22 and 22 for applying an adhesive to the upper and

lower coating films

21 and 21, but the adhesive application device and the application position are limited to the illustrated examples. Of course not.
[0031]
As shown in FIGS. 12 and 13, the upper and lower surface covering step is a step of supplying the

coating films

21 and 21 to the upper and lower surfaces of each heat insulator 19 and bonding the upper and lower surfaces of the heat insulator 19 with the upper and lower sealing machines 23. It is.
[0032]
The side surface covering step is a step of adhesively covering the left and right side surfaces in the transport direction of the heat insulator 19 with the covering film 21 in the both-side sealing machine 24.
[0033]
The end face coating / film separation step is performed by the front and rear end sealing machine 25.
The front and rear end surfaces in the transport direction of the heat insulator 19 are adhesively coated with a coating film 21, and the film 21 that is not covered is coated Insulation This is a step of cutting and separating from the step 19.
[0034]
Of course, the configuration of the sealing machine is not limited to the above-described configuration, and an integral seal or other sealing means can be used. FIG. 12 shows an example of an embodiment of the heat insulator 19 whose upper and lower surfaces and both left and right side surfaces are adhesively coated. FIG. 13 is a cross-sectional view perpendicular to the conveying direction. An example of an implementation is shown in a perspective view. FIG. 12 shows an embodiment in which the heat insulator 19 is formed by two inverted

elongated heat insulators

14 and 14, and the fiber orientation direction is perpendicular to the upper and lower surfaces of the heat insulator 19. 16 shows that the left and right side surfaces of 16 (heat insulator 19) are formed by the

lower surfaces

45, 45 of the vertically cut

elongated heat insulators

11, 11.
[0035]
A conveyance process is a process which sends the coating | coated heat insulation 27 with which the whole surface was coat | covered to the packing machine 28 by the conveying

apparatuses

26 and 26. FIG. As shown in FIG. 6, the next compression packing process is performed by aligning a predetermined number of coated insulating bodies 27 in the thickness direction and the width direction as shown in FIG. 6, and aligning insulating bodies 29 in the width direction as shown in FIG. And compressing the width direction compression alignment heat insulator 30. The coating film 21 is not damaged at all by the compression.
[0036]
The alignment heat insulators 29 are compressed only in the width direction due to the presence of a plurality of cured fiber orientation surfaces 43 formed in the individual heat insulators 19 in the parallel direction of the length direction and the thickness direction. In particular, the high-density fiber orientation surface 43 and the lower surface 42 formed in the vicinity of the deposited cotton 5 of the cotton collecting machine 4 are present on both sides of the heat insulator 19, so that the length direction and the thickness direction of the heat insulator 19. It also depends on the difficulty of compression.
[0037]
FIG. 8 to FIG. 11 show an example of the implementation of the inorganic heat insulating mat formed by the invention of claim 1 by sectional views perpendicular to the conveying direction.
[0038]
In FIG. 8, an example of the dry heat insulation molded object 9 after the dryer 8 is shown. FIG. 8 is a partial plan view of the molded body 9 having a width of 1000 mm after ear excision on both sides. The basis weight is 2150 g / m ² And
[0039]
FIG. 9 is a vertical cross-sectional view of the dried cross-sectional molded body 9. The orientation direction of the fiber blend surface 43 is a horizontal direction, and the thickness is formed to 225 mm. The lower surface 45 has a high fiber density.
[0040]
FIG. 10 shows longitudinally cut

elongated heat insulators

11 and 11 that are longitudinally cut by the longitudinal cutter 10. A dry heat insulating molded body 9 having a vertical cutting width of 100 mm and a width of 1000 mm is vertically cut into ten vertically cut elongated

heat insulating bodies

11 and 11. The thickness of the heat insulator 11 at this position is 225 mm, and the fiber orientation direction is horizontal.
[0041]
FIG. 11 shows the

heat insulating assemblies

16 and 16 after the aggregation machine 15. In the illustrated example, each heat insulating assembly 16 is formed by two longitudinally cut reverse elongated

heat insulating bodies

14 and 14.
The fiber orientation direction at this position is inverted by 90 ° in the vertical direction.
Each heat insulating assembly 16 has a width of 225 × 2 = 450 mm and a thickness of 100 mm.
[0042]
Accordingly, in the examples shown in FIGS. 8 to 11, the inorganic fiber 2 to which the adhesive after fiberization is applied is 2150 g / m. ² The basis weight of 1050 to 1100 mm width is collected to form an uncured fiber assembly 7. Next, the aggregate 7 was heated and molded to a molding thickness of 225 mm by a dryer 8, and then the ears on both sides were cut to a width of 1000 mm, and further longitudinally cut to a width of 100 mm, and 10 continuous pieces of 100 mm width were obtained. The longitudinally cut elongated

heat insulators

11 and 11 are strips having a rectangular cross section.
Next, the

individual heat insulators

11 and 11 are inverted in the direction of 90 ° opposite to each other in the conveying direction so that the

lower surfaces

45 and 45 are both side surfaces of the heat insulating assembly 16 as shown in FIG. The two heat-insulating

assemblies

16 and 16 are strips having a rectangular cross section having a thickness of 100 mm and a width of 450 mm.
Next, the heat insulating assembly 16 is cut into a specified dimension length of 1370 mm by a length cutter 18 to form a heat insulating body 19, and each of the

heat insulating bodies

19 and 19 is transported at a predetermined interval and is six-sided by a known means. Covered.
[0043]
FIG. 14 shows an example to which the invention of claim 2 is applied, and FIG. 26 shows each process diagram.
In the present invention, the steps up to the fiberizing step, the adhesive applying step, and the depositing and conveying step are the same as those of the first aspect of the present invention, and the description thereof will be omitted.
In the following, the same object is designated by the same number.
[0044]
In the next longitudinal cutting step, the uncured long fiber accumulation aggregate 7 is pressure-adjusted to a predetermined thickness by the press roller 31 while being conveyed by the conveyor 32, and then in the conveying direction by the vertical cutter 10. This is a step of longitudinally cutting to a predetermined width along with a plurality of rectangular cross-sections having a predetermined width to form an uncured vertically cut elongated heat insulator 33.
[0045]
The separation step is a step in which the plurality of rectangular cross-section elongated heat insulators 33 are separated from each other at a predetermined interval by the widening machine 12 and conveyed while maintaining the separation interval.
[0046]
Next, an inversion process is performed. This process is long in the assembly process which is the next process among the heat insulating bodies 33 while conveying the plurality of spaced rectangular cross-section elongated heat insulating bodies 33 by 90 ° in the direction orthogonal to the conveying direction. As shown in FIG. 11, the lower surface of the heat insulating body 33 is formed on the lower surface of the heat insulating body 33 as shown in FIG. This is a process of continuing the conveyance while turning 90 ° in the direction of the left and right side surfaces.
[0047]
In the assembling step, a plurality of uncured longitudinally cut rectangular cross-section reversal elongated heat insulators 34 having a predetermined width and a predetermined thickness are assembled in the collecting machine 15 so that their adjacent side surfaces are in contact with each other. This is a process for forming a single fiber assembly 35.
[0048]
The continuous mat drying forming process is a process in which the fiber assembly 35 is conveyed and heated in the dryer 8 and dried to a predetermined thickness to form a single continuous mat 36.
[0049]
In the width cutting step, the continuous mat 36 is vertically cut to a specified product width along the conveying direction by a vertical cutter 37 to form a plurality of vertical cut continuous mats 38, and the mats 38 are separated and held at a predetermined interval. It is the process of conveying while doing.
[0050]
Next, the steps after the length cutting step are the same as the steps of the first aspect of the invention, so that the description thereof is omitted.
[0051]
FIG. 15 is a partially enlarged plan view from the vertical cutter 10 to the reversing unit 13. In the illustrated example, the assembly 7 is cut into four vertically cut rectangular cross-section elongated

heat insulators

33 and 33 by the vertical cutter 10, and an intermediate illustration is omitted. The aspect which aggregates and becomes the single fiber assembly 35 is shown.
[0052]
FIG. 16 is a cross-sectional view perpendicular to the traveling direction of the assembly 7 indicated by a cutting line DD in FIGS. 14 and 15, and the orientation direction of the fiber orientation surface 43 is a horizontal direction. FIG. 17 is a cross-sectional view similar to the previous view of the fiber assembly 35 indicated by the cutting line EE, and the fiber orientation direction of the fiber assembly 35 after the reverse assembly is the vertical direction.
[0053]
In comparison with the uncured fiber assembly 35 obtained by reversing the uncured longitudinally cut rectangular cross-section elongated heat insulator 33 shown in the invention of claim 2 by 90 °, according to the method of the invention of claim 1,
a In the invention of claim 1, since the uncured aggregate 7 is conveyed to the dryer 8 with the fiber orientation direction kept horizontal as shown in FIG. 28, hot air for drying in the dryer 8 is provided. Is normally passed from the bottom to the top in the vertical direction (8 V direction), so that the hot air passes through each of the orientation surfaces 43 of the fibers and the lower surface 42 having a high density, the passage resistance is large, and the fibers are made of an adhesive. Since it is bonded and molded and skins are formed on the upper and lower surfaces, the thermal conductivity is reduced and the drying efficiency is slightly inferior. This trend is generally true for both low and high density products.
b According to the invention of claim 2, the uncured longitudinally cut rectangular cross-section elongated heat insulator 33 is inverted by 90 ° to form a longitudinally cut rectangular cross-section reflective elongated heat insulator 34, the heat insulators 34 are assembled, and the fiber orientation direction After the fiber assembly 35 is vertical, it is transported to the dryer 8 and dried by heating. From low density products to high density products (7 kg / m ³ ~ 200kg / m ³ Suitable for product manufacturing). In the dryer 8, as shown in FIG. 18, since the dry hot air passes between the fiber orientation surfaces 43, there is little airflow resistance of the dry hot air flowing vertically from bottom to top in the direction of arrow V during heating and drying. Compared with the invention of claim 1, since the passage of hot air is good, the drying efficiency is good, the ventilation energy and heating energy required for drying are both reduced, and the energy saving effect is increased.
[0054]
In addition, according to the manufacturing method of both invention of Claim 1 and Claim 2, since it is a continuous production system compared with the well-known manufacturing method of patent 2880933 invention, productivity becomes far better.
[0055]
As shown in FIGS. 1 and 16, the lower surface 42 of the assembly 7 formed in contact with the deposition surface 5 of the cotton collecting machine 4 has a fiber layer deposited on the suction chamber 47 from below the deposition surface. 28, the density of the lower orientation surface 43 close to the lower surface 42 becomes higher. In the invention of claim 1, the assembly 7 is conveyed to the dryer 8 in this state, and FIG. As shown, when the hot air V is passed from the bottom to the top and dried, the drying efficiency is higher than that of the invention of claim 2 because the passage of the hot air V is hindered by the high-density lower surface 42 side and the laminated orientation surface 43. Somewhat inferior, improvement in drying efficiency and reduction in drying cost cannot be expected.
[0056]
The numerical limitation in the invention of claim 8 will be described. The product width and product thickness dimensions of the product heat insulator 19 are:
Product width 390-600mm
Product thickness 50mm, 75mm, 100mm, 200mm
Therefore, the product should have the above dimensions. It is preferable that the number of the vertically cut elongated heat insulators 11 having a rectangular cross section constituting the heat insulator 19 is not large.
The reason is that as the number increases, the production process becomes more complicated, causing instability, and the factors such as the deterioration of the thermal conductivity of the heat insulator 19 due to the increase of the contact surfaces between the longitudinally cut elongated heat insulators increase. Because. Further, as shown in FIG. 23, if the width of the vertically cut elongated heat insulator 11 is X and the height is Y, the Y dimension cannot be so high. The reason for this is that it is necessary to increase the height of the dryer 6 shown in FIG. 1, which increases the equipment cost, and if Y is increased, the reversal structure when reversing 90 ° becomes difficult. Because appears.
[0057]
For the reasons described above, the appropriate width X, height Y value and X / Y ratio of the longitudinally cut elongated insulator 11 (abbreviated as elongated body in the table) for the existing equipment for the products having the product width and product thickness described above. Table 1 shows the values of the appropriate width and thickness of the heat insulating body 19 obtained by assembling a required number of the vertically cut reversal elongated heat insulators 14 after 90 ° reversal of the vertically cut slender heat insulators 11. Devised. In addition, since the width | variety of the heat insulating body 19 can be compressed in the width direction, it can be made a little larger than a required product width.
[0058]
Table 1

[0059]
As a result of consideration, it is possible to reduce the types of the width X and height Y of the elongated body necessary for manufacturing the product, and the necessary X / Y values are
X / Y = 1 / 0.65 to X / Y = 1 / 4.4
If it is within the range, it is sufficient, and if it is within the range, it is not necessary to modify the production equipment, and it has been found that the production cost is reduced.
24, as a representative example in Table 1, with a product thickness of 50 mm and a product width of 390 mm, the width of the elongated body is X = 50 mm, the height Y = 100 mm, and X / Y = 1 / 2.0. The necessary number to be produced is four, and the relationship that the heat insulator has a width of 400 mm and a thickness of 50 mm is shown. Therefore, a heat insulator having a width of 400 mm is used after being compressed to a width of 390 mm. The same applies to other calculation examples.
[0060]
【The invention's effect】
In the invention of claim 1,
a Since the coated inorganic heat insulating material in which the fiber orientation direction is perpendicular to the upper and lower surfaces and the conveying direction can be manufactured by a continuous process, the productivity is high.
b Since the longitudinally cut reversal elongated heat insulators can be formed into a heat-insulating aggregate having a required width, it can be produced by a cotton collecting machine having a narrow cotton collection width, for example, a narrow width of 1050 to 1100 mm.
c It becomes easy to make the density distribution in the width direction of the fiber on the narrow cotton collecting machine uniform, which improves the quality of the product, and the equipment of the cotton collecting machine, dryer and other processes is narrow. This is enough and the equipment cost is low.
d Since the coated insulation can be compressed and packed in the width direction while being coated, the product is less damaged, and the product storage cost and transportation cost are reduced.
There are various effects.
[0061]
In the invention of claim 2, in addition to the effects described in the preceding paragraph, the fiber orientation direction of the fiber assembly before entering the dryer is set to be perpendicular to the upper and lower surfaces, so that the drying efficiency and energy efficiency in the dryer are The effect which can be improved from the invention of claim 1 is produced.
[0062]
In the invention of the inorganic heat insulating mat according to claim 3, since the fiber orientation direction of the inorganic fibers is oriented in a direction parallel to the both side surfaces of the mat, the load is applied to the mat from the front-rear direction and the vertical direction. Further, the deformation resistance is large, and both sides of the mat are formed by the lower surface in contact with the accumulation surface of the cotton collecting machine, and the lower surface is the accumulation surface, and air is blown up on the perforated conveyor. As compared with the upper surface, the lower surface has a higher density, the adhesion rate of the adhesive to the fiber is higher, the surface of the lower surface in contact with the deposition surface is relatively smooth, and the lower surface skin is also strong. Therefore, the side skin of the mat is tough, the side surface is not easily deformed, and after unpacking the compressed packing mat, it can easily expand in the side direction, and is transported and stored by compressed packing. Sometimes it ’s compact, Hee, holding cost is inexpensive, the time of construction can be disposed without causing a gap between the two sides members such as studs and the like, an excellent effect to handle easy insulation work.
[0063]
In the invention of claim 4, according to the conventional manufacturing method, in order to increase the productivity, it is usually performed to widen the manufacturing width of the manufacturing line, and for that purpose, 7 kg / m ³ ~ 32kg / m ³ However, it was difficult to make the density distribution in the width direction uniform. Moreover, since it is compressed and packed in the thickness direction, it has the above-mentioned problems during construction and after construction.
According to the production method of the present invention, productivity can be maintained and produced even in a narrow production line, and the fiber orientation direction is parallel to the front-rear direction and the up-down direction. In addition, it is difficult to be deformed in the thickness direction, and there is an effect that it is possible to provide a product excellent in shape retention and a product having a uniform density distribution during transportation, storage and construction.
[0064]
In the invention of claim 5, the coated mat can be compressed only in the width direction while being coated, and it has the effect of reducing the cost of transportation and storage by compression packing, and the width of the coated mat remains uncoated after unpacking. It can be expanded only in the direction, and has the effect of becoming a product that is extremely suitable for thermal insulation work.
[0065]
In the invention of claim 6, the thickness dimension of the mat is substantially equal to the specified thickness dimension in both the compression packaging in the width direction and after the packaging is removed for construction, and the conventional thickness direction Unlike compressed products, there is no trouble of over-expansion or under-thickness in the thickness direction at the time of construction, there is no hindrance to the mat coating work, the coating film is not damaged, and the mounting surface Regardless of the variation in the distance between the two members in the width direction, there is no gap between the members due to the expansion, and there is no need for trouble in the construction, and the effect of reducing the construction cost is achieved.
[0066]
In the invention of claim 7, since the thickness and length of the mat are not changed before and after the compression packing and during the construction, the covering of the covering is maintained without damage to the covering. There is an effect that does not cause quality degradation.
[0067]
In the invention of claim 8, it is possible to cope with the required product dimensions without modifying the manufacturing equipment, and it is possible to reduce the types of longitudinally cut elongated insulators necessary for manufacturing the product. Therefore, the equipment cost is not increased, the production cost can be reduced, and further, it is possible to stably produce a high-quality heat insulating material.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a schematic side view of a manufacturing apparatus to which the invention of claim 1 is applied, up to before the upper and lower seals of a coating film on a heat insulator.
2 is a schematic side view of the manufacturing apparatus of FIG. 1 and subsequent figures.
FIG. 3 is a partially enlarged plan view of the manufacturing apparatus.
4 is a vertical sectional view taken along line AA in FIG. 3;
5 is a vertical cross-sectional view along BB in FIG. 3;
FIG. 6 is a perspective view showing a packing state before compression in the width direction.
FIG. 7 is a perspective view showing a packing state after compression in the width direction.
FIG. 8 is a partial plan view of an inorganic fiber aggregate after ear excision.
9 is a vertical cross-sectional view of the assembly of FIG. 8 in the conveyance direction.
FIG. 10 is a vertical sectional view in the conveying direction of a longitudinally cut elongated heat insulator.
FIG. 11 is a vertical sectional view of the heat insulating assembly obtained by assembling the vertically cut inverted elongated heat insulating members.
FIG. 12 is a vertical sectional view of the coated heat insulating body.
FIG. 13 is a perspective view of a coated heat insulator showing a six-surface coated state.
FIG. 14 is a schematic side view of an apparatus up to a coating film coating step of a manufacturing apparatus to which the invention of claim 2 is applied.
FIG. 15 is a partially enlarged plan view omitting the middle of the manufacturing apparatus.
16 is a vertical sectional view taken along line DD in FIGS. 1 and 15. FIG.
17 is a vertical cross-sectional view taken along line EE in FIGS. 1 and 15. FIG.
FIG. 18 is a vertical cross-sectional view in the conveying direction for explaining a hot air passage state of a fiber assembly in a dryer according to a second aspect of the present invention.
FIG. 19 is a vertical sectional view in the length direction of a conventional covering mat.
FIG. 20 is an explanatory diagram showing the arrangement of mats that have been longitudinally cut after cutting off the ears of a conventional product.
FIG. 21 is a longitudinal sectional view in the length direction showing an expanded state after construction of a conventional product.
FIG. 22 is a vertical sectional view showing the generation of a gap after the above construction.
FIG. 23 is a vertical sectional view of a longitudinally cut elongated heat insulator.
FIG. 24 is a diagram illustrating the relationship between the product cross-sectional view and the required longitudinally cut elongated heat insulator cross-sectional view.
FIG. 25 is a process diagram of the first aspect of the present invention.
FIG. 26 is a process diagram of the invention of claim 2;
FIG. 27 is a vertical cross-sectional view perpendicular to the conveying direction showing an assembly that is suction-deposited on the accumulation surface of the cotton collecting machine.
FIG. 28 is a vertical cross-sectional view perpendicular to the conveying direction for explaining the state of hot air passing through the aggregate in the dryer according to the first aspect of the present invention.
[Explanation of symbols]
1 Fiberizer
2 Inorganic fiber
3 Adhesive spray
4 Cotton collecting machine
5 deposition surface
6 Transporter
7 Aggregate
8 Dryer
9 Dry insulation molded body
10 Vertical cutter
11 Longitudinal cutting insulation
12 Widening machine
13 Inversion part
14 Longitudinal cut reversal insulation
15 Collecting machine
16 Thermal insulation assembly
17 Presser roller
18 length cutting machine
19 Insulation
20 Stopper
21 Coating film
22 Adhesive spray
23 Vertical seal machine
24 Double side sealing machine
25 Front and rear end sealing machine
26 Conveyor
27 Insulated insulation
28 Packing machine
29 Aligned insulation
30 Width direction compression aligned insulation
31 Presser roller
32 Transporter
33 Longitudinal cut rectangular cross-section elongated insulator
34 Longitudinal cut rectangular cross-section reversal elongated insulator
35 Fiber assembly
36 continuous mats
37 Vertical cutter
38 Vertical cutting continuous mat
43 Orientation plane
44 Top view
45 Bottom

Claims

A fiberizing process for fiberizing inorganic raw materials with a fiberizing device;
An adhesive application step of applying an adhesive to the inorganic fiber after fiberization;
A stacking and transporting step in which uncured fibers after application of the adhesive are sequentially dropped onto a planar deposition surface and deposited in layers and transported to form a long aggregate; and
A compression drying step of compressing and heating to a predetermined thickness while sequentially transporting uncured long fiber accumulation aggregates, and forming a dry heat insulating molded body of a predetermined thickness,
A longitudinal cutting step of cutting the long dried heat-insulated molded body to be transported into a predetermined width along the transport direction to form a vertically cut elongated heat insulating body having a plurality of rectangular cross sections having a predetermined width;
A separation step of separating the plurality of rectangular cross-section elongated insulators from each other at a predetermined interval, and carrying while maintaining the separation interval;
When the plurality of separated longitudinally cut elongated heat insulators are inverted 90 ° in the direction perpendicular to the conveying direction, respectively, and among the heat insulators, they are assembled into a long heat insulation assembly in the next assembly step, In the heat insulator that is on both the left and right outer sides of the assembly, a reversing step in which the lower surface of the heat insulator is reversed by 90 ° in the direction that becomes the left and right side surfaces of the assembly, respectively, and the conveyance is continued.
A plurality of longitudinally cut reversing elongated heat insulators having a predetermined width and a predetermined thickness are gathered to a predetermined number with the interval between them set to 0, and a predetermined product width is maintained while holding the reversal state of the reversing slender heat insulators by a presser roller. An assembly process for conveying the product with a long heat insulation assembly,
After cutting a long heat insulation assembly into a heat insulator of a specified product length, a length cutting step for conveying the heat insulation with a predetermined front-rear interval,
An adhesive application step of applying an adhesive to at least one of the upper and lower surfaces of each heat insulator and the heat insulator contact surface of the coating film;
A coating film is supplied to each of the upper and lower surfaces of each insulator, and an upper and lower surface covering step for adhesively covering the upper and lower surfaces of the insulator,
A side surface coating step for adhesively covering the left and right side surfaces in the transport direction of the heat insulator with a coating film;
An end surface coating / film separation step of adhesively coating both front and rear end surfaces of the heat insulating body with a coating film, and cutting and separating the uncoated film from the heat insulating body,
A transporting process for sending a thermal insulation coated on the entire surface to the packing machine;
A continuous manufacturing method of a coated inorganic heat insulating mat comprising a compression packing step of aligning a predetermined number of coated heat insulators in a thickness direction and a width direction with a packing machine, and compressing and packing the aligned heat insulators in the width direction.

A fiberizing process for fiberizing inorganic raw materials with a fiberizing device;
An adhesive application step of applying an adhesive to the inorganic fiber after fiberization;
While the uncured fiber after adhesive application and transport tighten allowed sedimentary layered are sequentially dropped onto the flat deposition surface and depositing conveyor forming a very long assembly,
Longitudinal cutting of uncured long fiber pile assembly to a predetermined thickness and then cut into a predetermined width along the conveying direction to form a vertically cut elongated heat insulator having a plurality of rectangular cross sections with a predetermined width Process,
A separation step of separating the plurality of rectangular cross-section elongated insulators from each other at a predetermined interval, and carrying while maintaining the separation interval;
The plurality of separated rectangular cross-section longitudinally cut elongated heat insulators are inverted by 90 ° in the direction orthogonal to the conveying direction, respectively, and are gathered into a long fiber aggregate in the next assembly step of the heat insulators. At the same time, in the heat insulating body that is the left and right outer surfaces of the assembly, a reversing step of continuing the conveyance while reversing the lower surface of the heat insulating body by 90 ° in the direction of the left and right side surfaces of the assembly; ,
A plurality of rectangular cross-section elongated heat insulators having a predetermined width and a predetermined thickness, assembled so that their adjacent side surfaces are in contact with each other, and an assembly step to form an uncured long fiber assembly;
A continuous mat drying forming step in which the fiber assembly is transported and heated to be dry-molded to a predetermined thickness to form a continuous mat;
A width cutting step in which the continuous mat is longitudinally cut to a specified product width along the transport direction, and a plurality of longitudinally cut continuous mats are transported while being held apart from each other at a predetermined interval;
A length cutting step of transporting the specified width cut continuous mat to a heat insulator of a specified product length after being separated by a predetermined front-rear interval;
An adhesive application step of applying an adhesive to at least one of the upper and lower surfaces of each heat insulator and the heat insulator contact surface of the coating film;
The upper and lower surfaces of each insulator supply upper and lower surfaces respectively by supplying a coating film, and adhesively covering the upper and lower surfaces of the insulator,
A side coating process in which both left and right sides in the transport direction of the heat insulating body are adhesively coated with a coating film, and end face coating in which both front and rear end surfaces in the transport direction of the heat insulating body are adhesively coated with a coating film, and the uncovered film is cut and separated from the heat insulating body.・ Film separation process,
A transporting process for sending a thermal insulation coated on the entire surface to the packing machine;
A continuous manufacturing method of a coated inorganic heat insulating mat comprising a compression packing step of aligning a predetermined number of coated heat insulators in a thickness direction and a width direction with a packing machine, and compressing and packing the aligned heat insulators in the width direction.

An inorganic heat insulating mat as a molded product having a rectangular parallelepiped width, length and thickness made of an aggregate of inorganic fibers, wherein the mat is assembled by inverting 90 ° of a vertically cut elongated heat insulating body having a rectangular cross section. The fiber orientation during fiber deposition, which is the fiber orientation direction of the inorganic fibers, is oriented in a direction parallel to both side surfaces of the mat, and is therefore oriented in a direction substantially perpendicular to the top and bottom surfaces and both end surfaces of the mat, Further, both side surfaces of the mat are formed by the lower surface of the longitudinally cut elongated heat insulator, and further, the respective fibers constituting the mat are bonded to each other with a thermosetting resin, and the entire surface of the rectangular parallelepiped is covered with a covering material. , no machine quality insulating mat produced by has been continuous process according to any one of claims 1 or 2.

The coated inorganic insulating mat according to claim ³ , wherein the density is 7 kg / m ^{3 to} 32 kg / m ³ .

The coated inorganic heat insulating mat according to claim 3 or 4, wherein the inorganic heat insulating mat compressed and packed at the time of packing is compressible only in the width direction.

The thickness and length of the inorganic heat-insulating mat, which is a rectangular parallelepiped molded product, are substantially the same as the specified thickness and length regardless of whether it is compressed or packed in the width direction. A coated inorganic insulating mat according to claim 3, 4 or 5, which is equal to:

The coated inorganic heat insulating material according to claim 3, 4, 5, or 6, wherein each surface of the inorganic heat insulating mat is coated with a covering material regardless of before and after the compression packing and during construction. mat.

The heat insulation assembly is formed by assembling at least two longitudinally cut reversal elongated heat insulators obtained by reversing a vertically cut slender heat insulator having a rectangular cross section in parallel in the lateral direction of the heat insulation assembly, The ratio of the width dimension X to the height dimension Y of the longitudinally cut elongated insulator is in the range of X: Y = 1: 0.65 to 1: 4.4. The coated inorganic heat insulating mat according to claim 6 or 7.