JPS5930544B2 - Method for producing coated inorganic fiber mat - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing coated inorganic fiber mats.

Inorganic fiber mats (hereinafter simply referred to as mats) such as glass wool mats have excellent heat insulation and sound absorption properties, and are useful for building insulation,
It is widely used for sound absorption, etc., but in most cases, the mat is covered with a covering material that has high moisture permeability resistance to prevent fibers from scattering, improve moisture permeation resistance performance, and improve installation workability. occupy (・ru.

Products that use a combination of a thermoplastic film with an aluminum layer and a paper-like material such as kraft paper with an asphalt layer as enveloping materials are industrially produced in large quantities, and the applicant is This product (hereinafter referred to as the matte product) is marketed as (trade name) (・
Ru. This mat product has a wider width than the mat.
In addition, one side of the mat is made of a thermoplastic plastic film with an aluminum layer on its surface (hereinafter referred to as Al-film), and one side of the mat is a flat paper-like material (hereinafter referred to as asphalt paper) with a poultice of asphalt that is wider than the mat. The other side of the mat is covered with (U), and the mat and Al-film are adhered to the paper-like material by asphalt, making them integral.

Figures 1 and 2 are drawings schematically showing an example of the cross-sectional structure of the mat product.

Figure 1 shows the structure of Matsuto Ace Silver (product name), where 1 is glass fiber mat, 2 is A1 = film,
Thermoplastic film 3 and aluminum layer 4
It is manufactured by, for example, vacuum-depositing aluminum onto a film, and the aluminum layer is tightly adhered to the film.

5 is asphalt paper with high strength like kraft paper (
- It is composed of a paper-like material 6 and an asphalt layer 7 coated on one side thereof, and both the Al-film and the asphalt paper have a width wider than that of the mat.

The Al-film covers the top surface of the mat with the aluminum layer on the outside, and its ends are folded inward to wrap around the sides of the mat to cover the bottom surface of the mat near the sides. Then, the folded part 8 of the film covering the bottom surface of the mat and the center part of the bottom surface of the mat (covered with the film)
The aluminum layer 4 is bonded to the paper-like material 6 with asphalt, and these three parts are bonded together. The asphalt is in contact with the aluminum layer 4, and the film is in direct contact with the asphalt. Figure 2 shows another example of the matte product of the present invention, in which the Al film 2 is folded outward from the mat side, and the Al film is folded back. The portion 8 is adhered to the edge portion 9 of the asphalt paper 5 with asphalt.

In this example, the aluminum layer is provided on the surface that should be in contact with the asphalt. The matte product covered with Al-film and asphalt paper has excellent performance such as good heat insulation, high heat reflection effect at °C, high moisture permeation resistance at °C, and easy installation. Industrially, it is produced continuously using long lengths of pine, Al-film, and asphalt paper, but it has been found that the following problems arise in its production.

(1) This pine product is industrially produced continuously. That is, Al-film and asphalt paper are continuously supplied from a roll to the upper and lower surfaces of the wool, and after bending the ends of the Al-film at a predetermined position using a roll, etc., the asphalt is fused with the roll. It is manufactured by compressing and bonding the Al-film and mat to a paper-like material using the molten asphalt. Because the mat and Al film are soft, it is difficult to position them, and their relative positions easily shift. Especially for the structure shown in Figure 1, Al-
Misalignment of the film cannot be detected by visual inspection of the product, and as shown in Figure 3, there is a possibility that misaligned A1 film may be mixed into the product, and the Al film is likely to peel off during use. . (2) The adhesive strength between aluminum and asphalt is greater than the adhesive strength between film and asphalt.Regardless of the temperature, the adhesive strength of aluminum and asphalt is greater than that of film and asphalt.
It has been found that peeling is more likely to occur compared to the case where the aluminum layer is placed on the surface of the film that should be in contact with the asphalt, and that adhesion problems are more likely to occur when the aluminum layer is provided on the surface of the film that should be in contact with the asphalt.

(3) The insulation performance can be improved by providing each aluminum layer, but since it is opaque, the asphalt layer in the ears is hidden in the structure shown in Figure 2.
It is not possible to determine from the appearance whether the asphalt is applied uniformly or not.The inventor of the present invention has conducted repeated studies to solve this problem, and as a result, the inventors have removed the part of the thermoplastic film that is in contact with the asphalt. The above (1) to (3) can be achieved by providing an aluminum layer of a predetermined thickness only in the central part.
In addition, particularly good results can be obtained by forming a boundary region in which the amount of aluminum deposited gradually decreases between the area where the aluminum layer is applied and the area where the aluminum layer is not applied. This is what we have discovered and proposed as the present invention.

Next, the present invention will be explained in more detail.

FIG. 4 is a concrete example of a method for continuously manufacturing the matte product, in which an Al film 42 is rolled into a roll 41.
It is pulled out with pull-out rolls 44, 44' while being pressed with presser rolls 43, 43', introduced onto a hardened glass wool mat 45, and wrapped with rolls 46, 46', 47,
47', 48, 48', 49, 49', 50, 5σ, 5
1, 5V, 52, 53, 54 (some of them are not visible because they are in blind spots, so there are no numbers (・ are arranged in the same way on both sides) (
・ru) to both sides, ・ru) to the bottom surface,
A partially covered glass wool mat 55 is formed by inserting the glass wool into the upper surface, both side surfaces, and both ends of the lower surface and wrapping the ends with an Al film. While holding it down with the kraft paper 57, the paper is pulled out with the pull-out rolls 59, 59', and the molten asphalt coating device 60 applies asphalt 61 to the entire surface of the kraft paper 57 except for the width direction edges. Laminated and conveyor 62,6
2' to apply pressure and adhere.

However, in Figure 4, supporting devices for various rolls, driving devices, and mere conveyance rolls are omitted, and the number, direction, length, size, etc. of rolls are merely examples. This is not intended to limit the invention in any way.

Also, instead of the conveyors 62, 62', rolls can be used for extrusion. The thermoplastic film that should constitute the A1 film includes polyethylene, polyester,
Plastic films such as polyvinyl chloride, polyvinylidene chloride, and polypropylene can be used. The thickness of the film is preferably 8 to 30 microns, preferably 10 to 20 microns. It is most practical to form the aluminum layer by vacuum deposition, and its thickness is 4 x 122.
It is appropriate to set it to around λ.

In addition, it is appropriate that the width of the boundary area is about 3 to 10 cm, and the width of the part in contact with the asphalt is about 3 to 8 c1n. Asphalt paper is preferably made of relatively hard paper with a weight of about 40 to 60 grams per meter, and suitable results can be obtained by using kraft paper, hotbed base paper, pure white roll paper, etc. be able to. The amount of asphalt applied is preferably about 30 to 100 gr per M2, and good results were obtained by applying the melt heated to about 150 to 230°C. In addition,
As the paper-like material, a laminate of paper and plastic or a laminate of paper and aluminum foil can also be used. On the upper surface of the Al-film 42, an aluminum vapor-deposited layer of a constant thickness is provided in the area inside the broken line 70, and no aluminum is vapor-deposited in the area outside the broken line 70 (. Since the A1-film is constructed in this way, if the position of the Al-film deviates from the normal position, the transparent film without vapor-deposited aluminum will cover the side of the mat (and the colored mat will disappear). can be seen through the film, making it extremely easy and reliable to discover positional deviations.

Furthermore, in the product shown in FIG. 2, the asphalt adhesive layer can be seen through, so it is easy to detect uneven asphalt application. Furthermore, when using the method of the present invention, the parts on which aluminum is vapor-deposited and the parts on which aluminum is vapor-deposited (. By using an optical method to detect the position of the boundary line between the part where aluminum is vapor-deposited and the other part, it is possible to easily detect the positional shift of the Al film. The position of the film can always be maintained at a predetermined position.

For example, the position of the Al film can be controlled by controlling the inclination, rotational speed, etc. of the envelope roll according to this detected value. Note that this control can also be performed manually. When depositing aluminum, a non-deposited region can be formed by masking, but by controlling the distance of this masking member from the film surface, the amount of aluminum deposited can be controlled inside or outside the boundary line 70 depending on the amount of deposited aluminum. Using an Al-film with such a border area, a decreasing translucent border area can be formed (
・If the boundary area is detected and controlled, the control can be performed over a certain width, so the position control of the Al film is better than when performing 0N-0FF control using a single boundary line. It turns out that it can be done.

Furthermore, it has been found that by providing the aluminum-coated portion and the free portion as described above, it is difficult for the Al film to shift from its normal position.

The reason for this is not completely clear, but since the rigidity of the film changes suddenly at the boundary line or boundary area, the film tends to bend at this part. It is thought that since the film is folded back in the boundary area, the folding position is self-retaining. Furthermore, FIGS. 5 and 6 are drawings schematically showing the cross section of the coated inorganic fiber mat of the present invention, and FIGS. 5 and 6 correspond to FIGS. 1 and 2, respectively. It is.

In the case of Figures 1 and 2, the aluminum layer is provided on the surface that should be in contact with the asphalt and is in contact with the asphalt, whereas in the case of Figures 5 and 6. At ℃, the aluminum layer in this part is removed, and the asphalt is in direct contact with the thermoplastic resin film.The adhesive strength between aluminum and asphalt is greater than that between the film and asphalt. Although it is not clear why this phenomenon occurs regardless of the temperature, it is thought that thermal fusion occurs partially when the film comes into contact with the high-temperature molten asphalt.Therefore, even if an aluminum layer is provided on the surface to be bonded to the asphalt, No reduction in adhesive strength occurs.As described above, when using the method of the present invention, it is easy to position the Al film and the mat relative to each other and to control the position. Even if it does occur, it can be easily discovered and the adhesive strength is high, making the present invention industrially useful.

[Brief explanation of drawings]

1 to 3, 5, and 6 are exploded views of the coated inorganic fiber mat, and FIG. 4 is an explanatory diagram showing a method of manufacturing the coated inorganic fiber mat. In the figure, 1 is an inorganic fiber mat, 2 is a thermoplastic resin film coated with an aluminum layer, and 5 is a paper coated with asphalt.

Claims (1)

[Claims] 1. One side of the inorganic fiber mat is covered with a thermoplastic plastic film wider than the mat, and the other side is covered with a paper-like material coated with asphalt, which is wider than the mat, and the mat and film are covered with asphalt. A method for producing a coated inorganic fiber mat that is bonded and integrated with an object, characterized in that a thermoplastic film is coated with an aluminum layer to a predetermined thickness except for the part that comes in contact with asphalt. Method for manufacturing fiber mats. 2. The coating according to claim 1, characterized in that a boundary region in which the amount of aluminum deposited gradually decreases is formed between the part to which the aluminum layer is deposited and the part to which it is not deposited. A method for producing an inorganic fiber mat. 3. The method for producing a coated inorganic fiber mat according to claims 1 and 2, characterized in that the aluminum layer is provided on the surface of the thermoplastic film that is to be in contact with asphalt.