CN119305095A - High-strength rock fiber board production process - Google Patents
High-strength rock fiber board production process Download PDFInfo
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- CN119305095A CN119305095A CN202411452440.0A CN202411452440A CN119305095A CN 119305095 A CN119305095 A CN 119305095A CN 202411452440 A CN202411452440 A CN 202411452440A CN 119305095 A CN119305095 A CN 119305095A
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Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B04—CENTRIFUGAL APPARATUS OR MACHINES FOR CARRYING-OUT PHYSICAL OR CHEMICAL PROCESSES
- B04C—APPARATUS USING FREE VORTEX FLOW, e.g. CYCLONES
- B04C7/00—Apparatus not provided for in group B04C1/00, B04C3/00, or B04C5/00; Multiple arrangements not provided for in one of the groups B04C1/00, B04C3/00, or B04C5/00; Combinations of apparatus covered by two or more of the groups B04C1/00, B04C3/00, or B04C5/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
- B07B9/00—Combinations of apparatus for screening or sifting or for separating solids from solids using gas currents; General arrangement of plant, e.g. flow sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/006—Pressing and sintering powders, granules or fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/30—Making multilayered or multicoloured articles
- B29C43/305—Making multilayered articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
- B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/545—Perforating, cutting or machining during or after moulding
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/38—Fibrous materials; Whiskers
- C04B14/46—Rock wool ; Ceramic or silicate fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2007/00—Flat articles, e.g. films or sheets
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Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Ceramic Engineering (AREA)
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- Materials Engineering (AREA)
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- Organic Chemistry (AREA)
- Civil Engineering (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
Abstract
本发明涉及一种高强岩纤板生产工艺，方法包括以下步骤：将成捆的岩棉原料包依次进行解纤、筛分与风选，获得制板需要的纤维坯料及粉料坯料；将纤维坯料及粉料坯料分别与对应的胶粉混合，得到纤维胶料混合体和粉料胶料混合体；将粉料胶料混合体和纤维胶料混合体送入对应的铺装机，按物料精准计量进行铺装，并进入预压机预压和排气成型，得到具有初步结合力的制板板坯；将制板板坯送入柔性连续压机进行高温高压压制处理，形成制板板材；将制板板材进行裁边锯切、表面砂光抛光、分拣打包，形成高强岩纤板。本发明，提高了岩纤板的强度、承载能力、稳定性及耐用性。
The present invention relates to a high-strength rock fiber board production process, the method comprises the following steps: defibration, screening and air separation of bundled rock wool raw material packages in sequence to obtain fiber blanks and powder blanks required for board making; mixing the fiber blanks and powder blanks with corresponding rubber powders respectively to obtain fiber-rubber mixtures and powder-rubber mixtures; sending the powder-rubber mixtures and the fiber-rubber mixtures into corresponding paving machines, paving according to accurate material measurement, and entering pre-pressing machines for pre-pressing and exhaust molding to obtain board blanks with preliminary bonding force; sending the board blanks into flexible continuous presses for high-temperature and high-pressure pressing treatment to form board plates; trimming and sawing the board plates, sanding and polishing the surfaces, sorting and packaging to form high-strength rock fiber boards. The present invention improves the strength, bearing capacity, stability and durability of rock fiber boards.
Description
Technical Field
The invention relates to a production process of a high-strength rock fiber board.
Background
At present, rock wool fibers are used as an excellent inorganic fiber material, have good heat preservation and insulation, flame retardance, no toxicity, environmental protection and other performances, and are widely applied to the fields of construction, industry and the like, but the rock wool plates are usually manufactured by a simple paving and hot pressing process, the density of manufactured products is mostly 60-200kg/m 3, the strength is lower, the bearing capacity, the stability and the durability are poorer, the rock wool fibers are daily applied as filling materials or surface-attached metal plates, the construction difficulty and the application cost are increased, and the use effect is also influenced; the method for manufacturing the wood density board comprises the steps of adding water-based adhesive into rock wool fibers, performing hot press molding by using an air flow paving and gap pressing machine, wherein the density and strength of a finished product are greatly improved, but the water content is high, fiber clusters are difficult to break up, abnormal or insufficient phenomena such as board bursting and bubbling occur in a hot press process, quality stability and high raw material consumption of the finished product are affected, the method for manufacturing the wood density board by spraying resin into the rock wool fibers through heating and solidifying and molding is also adopted, but the sizing mode and the pressurizing pressure are limited, the density uniformity and flatness deviation of the finished product are affected, the method for manufacturing the rock wool fibers and silicate cement through hot press molding is also adopted, the density is improved, the cost is reduced, but the toughness and the surface bonding strength of the finished product are affected, the production efficiency is lower, and the method for manufacturing the rock wool board by adopting a heating and pressing roller has simple equipment, but the temperature difference and the high roll surface pressure are easily deformed, and the positive plate thickness and density uniformity are affected.
However, the conventional manufacturing method of the rock fiber boards generally adopts a gap type multi-layer press or a single-layer press or synchronous lifting type continuous press equipment, the thickness, uniformity and strength performance of the finished product boards are difficult to control, the surface bonding strength and the board surface screw holding force are low, the quality influence is large, and the production efficiency is low.
Disclosure of Invention
The invention aims to provide a high-strength rock fiber board production process for improving the density, strength and product quality of the rock fiber board.
In order to achieve the above object, the present invention provides a high-strength rock fiber board production process based on a set of high-strength rock fiber board production equipment including a flexible continuous press, the high-strength rock fiber board production equipment including a raw material preparation section, a blank sizing section, a slab paving forming section, a continuous press forming section and a post-treatment finished product section, the high-strength rock fiber board production process comprising the steps of:
Step S1, sequentially carrying out defibration, screening and winnowing on a bundle of rock wool raw material bags in the raw material preparation section to obtain fiber blanks and powder blanks required by plate making;
S2, in the blank sizing section, respectively mixing the fiber blank and the powder blank with corresponding rubber powder to obtain a fiber-rubber compound mixture and a powder-rubber compound mixture;
s3, in the slab paving and forming section, feeding the powder-rubber mixture and the fiber-rubber mixture into corresponding paving machines, paving according to accurate material metering, and feeding the materials into a prepressing machine for prepressing and exhausting and forming to obtain a slab with primary bonding force;
s4, continuously pressing the plate blank into a section, and conveying the section into a flexible continuous press for high-temperature high-pressure pressing treatment to form a plate blank;
And S5, in the post-treatment finished product section, cutting edges, sawing, polishing, sorting and packaging the plate, so as to form the high-strength rock fiber plate.
According to one technical scheme of the invention, the raw material preparation section comprises a defibrator, a classifying screen, a fiber winnowing machine, a powder winnowing machine, a first cyclone separation device, a second cyclone separation device, fiber storage equipment, powder storage equipment and a tail gas treatment device;
The fiber-separating machine is used for packing Jie Qian the bundled rock wool raw materials to obtain rock fiber materials, the classifying screen is used for screening the rock fiber materials to obtain fiber blanks and powder blanks required by plate making, and a conveyor belt is arranged between the fiber-separating machine and the classifying screen;
The fiber separating machine, the classifying screen, the fiber fanning machine, the first cyclone separation device, the fiber storage equipment and the tail gas treatment device form a fiber blank preparation process section;
The defibrator, the classifying screen, the powder winnowing machine, the second cyclone separation device, the powder storage equipment and the tail gas treatment device form a powder blank preparation process section;
the first cyclone separation device and the second cyclone separation device are used for removing impurities and selecting materials;
the fiber storage device is arranged at the lower end of the first cyclone separation device, and the powder storage device is arranged at the lower end of the second cyclone separation device.
According to one technical scheme of the invention, the blank sizing section comprises a first metering conveyor, a second metering conveyor, a secondary fiber-dissolving machine, a first glue mixing system and a second glue mixing system;
The first metering conveyor is arranged at the discharge end of the fiber storage device, and the secondary fiber-dissolving machine is arranged between the first metering conveyor and the first glue mixing system;
The second metering conveyor is arranged at the discharge end of the powder storage device and is directly connected with the second glue mixing system;
the fiber discharge port of the secondary fiber-separating machine is connected with the first glue mixing system, and the powder discharge port is connected with the second glue mixing system through a third cyclone separation device;
the first cyclone separation device, the second cyclone separation device and the third cyclone separation device are all connected with the tail gas treatment device.
According to one technical scheme of the invention, the first glue mixing system and the second glue mixing system are both provided with reaction kettles for preparing glue powder, and the first metering conveyor and the second metering conveyor are both composed of a meter and a distributing conveyor;
the rubber powder is one or more of phenolic resin, urea resin, carbon dioxide resin or polyester resin;
the fiber-size mixture and the powder-size mixture are also blended with an oil thermoplastic composite.
According to one technical scheme of the invention, the slab paving and forming section comprises a forming conveyor, a plurality of surface layer paving machines and at least one core layer paving machine, wherein the surface layer paving machines and the core layer paving machines are arranged along the forming conveyor, blanks are distributed on a belt of the forming conveyor below in a layering manner according to numerical control proportion to form fluffy slabs, the forming conveyor is provided with a plurality of weighing devices, the tail end of the forming conveyor is provided with a preformer and a longitudinal edge saw, the preformer is used for exhausting and prepressing the fluffy slabs, and the longitudinal edge saw is used for trimming the side edges of the prepressed slabs;
any surface layer paving machine comprises a feeding belt, a first metering belt, a first dispersing roller and a paving toothed roller;
The core layer paving machine comprises a material distributing device, a metering bin, a second metering belt, a plurality of second scattering rollers, a paving box, a plurality of layers of star cage rollers and a plurality of leveling rollers, wherein the second scattering rollers and the plurality of layers of star cage rollers are used for uniformly paving fiber materials on a surface layer slab;
The rollers of the first scattering roller and the second scattering roller are in a knife roller shape, and the star cage rollers are cage rollers with slender rods distributed circumferentially.
According to one technical scheme of the invention, the continuous pressing and forming section comprises a plate loading conveyor, the flexible continuous press and an electric control system;
The plate loading conveyor is arranged between the flexible continuous press and the forming conveyor and is used for conveying the pre-pressed plate blanks into the flexible continuous press;
The flexible continuous press is used for carrying out heating and pressurizing treatment on the pre-pressed slab;
the electric control system is used for controlling the working parameters of the flexible continuous press.
According to one technical scheme of the invention, the flexible continuous press comprises a lower driven roller, a lower steel belt, a lower roller blanket, a frame group, a lower hot pressing plate, an inlet hot pressing plate, an upper hot pressing plate, an oil cylinder, a lower driving roller, an upper steel belt, an upper roller blanket, an upper driven roller, an upper feeding head, an inlet lifting group, an electric system, a hydraulic system and a heating system;
The upper hot pressing plate, the lower hot pressing plate, the upper roller blanket, the lower roller blanket, the upper steel belt and the lower steel belt form a slab pressing working section, and the slab pressing working section is arranged in the middle of the flexible continuous press;
The plurality of oil cylinders are arranged on the upper surface of the upper hot pressing plate according to the array of the pressing force, and the upper hot plate of the working section is in a micro flexible wave curve state in the longitudinal direction and in a concave arc state in the transverse direction by adjusting the pressure of each oil cylinder and the displacement of the extending end of each oil cylinder.
According to one technical scheme of the invention, the slab pressing working section sequentially comprises a high-pressure exhaust heat transfer section, a medium-pressure heat preservation curing section, a low-pressure thickness fixing section and a pressure relief heat dissipation section, wherein the electric control system is an electric PID closed-loop control system, and the electric control system is adopted to adjust the board-making hot-pressing process parameters of any working section and the associated speed parameters and displacement parameters of the paving machine;
the board-making hot-pressing technological parameters at least comprise pressurizing time, pressure, displacement and temperature.
According to one aspect of the invention, the post-treatment manufactured product segment comprises a trimming saw, a density detector, a sander, a surface detector, and a sorting packer system.
According to one technical scheme of the invention, the thickness deviation of the high-strength rock fiber board produced based on the steps S1 to S5 is smaller than 0.1mm, the average density is 900-1400kg/m 3, the static bending strength is not smaller than 25MPa, the elastic modulus is not smaller than 4000MPa, the surface layer bonding strength is not smaller than 1.2MPa, the board holding screw force is not smaller than 30KN, and the water absorption thickness expansion rate is not larger than 4% in 24 hours.
Compared with the prior art, the invention has the following beneficial effects:
According to the high-strength rock fiber board production process adopting the flexible continuous press complete equipment, the rock cotton fibers are treated by using the complete high-strength rock fiber board production equipment comprising the flexible continuous press, and the complete equipment finally and directly obtains the high-strength rock fiber board, so that the strength, the bearing capacity, the stability and the durability of the rock fiber board are improved.
The high-strength rock fiber board production process is realized by using the flexible continuous press, wherein the up-and-down displacement position of the hot pressing plate can be accurately positioned to realize a flexible curved surface, the hot pressing temperature and the hot pressing pressure at different positions in the production direction (or longitudinal direction) can be set according to the production process requirement, the product quality of a pressed product is obviously improved, and the production pressurizing time, the temperature, the pressure, the displacement and other plate hot pressing process parameters are formula values which are required to be regulated by adopting an electric PID closed-loop control system, so that the invention has the advantages of high automation level, convenient operation, convenient control and the like, and is beneficial to improving the production efficiency.
Further, the multilayer paving structures of the surface layer paving machine and the core layer paving machine effectively improve the surface layer bonding strength and the plate surface screw holding force of the rock fiber plate, and the manufactured plate has excellent physical and mechanical properties.
The high-strength rock fiber board obtained by the high-strength rock fiber board production process has the thickness deviation of less than 0.1mm, the average density of 900-1400kg/m 3, the static bending strength of not less than 25MPa, the elastic modulus of not less than 4000MPa, the surface bonding strength of not less than 1.2MPa, the board holding screw force of not less than 30KN and the water absorption thickness expansion rate of not more than 4% in 24 hours.
Drawings
FIG. 1 schematically illustrates a flow chart of a process for producing a high strength fiberboard in accordance with one embodiment of the present invention;
FIG. 2 schematically illustrates a schematic process flow diagram of a kit according to one embodiment of the invention;
FIG. 3 schematically illustrates an apparatus for a core paving machine according to one embodiment of the present disclosure;
FIG. 4 schematically illustrates an apparatus schematic of a flexible continuous press according to one embodiment of the invention;
FIG. 5 schematically illustrates a cylinder arrangement of a flexible continuous press according to one embodiment of the invention;
FIG. 6 schematically illustrates a hot plate operating state (longitudinal) diagram of a flexible continuous press according to one embodiment of the present invention;
FIG. 7 schematically illustrates a hot plate operating state (transverse) diagram of a flexible continuous press according to one embodiment of the present invention;
FIG. 8 schematically illustrates an electrical PID closed loop control system according to an embodiment of the invention;
FIG. 9 schematically illustrates an apparatus of the skin shop machine according to an embodiment of the invention;
fig. 10 schematically illustrates an enlarged schematic view at a of fig. 4 according to one embodiment of the present invention.
The correspondence between the reference numerals and the component names in fig. 1 to 10 is:
1. the device comprises a fiber separating machine, a classifying screen, a fiber fanning machine, a first cyclone separating device, fiber storage equipment, a first metering conveyor, a second fiber separating machine and a second metering conveyor, wherein the fiber separating machine comprises a fiber separating machine, a classifying screen, a fiber fanning machine, a first cyclone separating device, a fiber storage device, a first metering conveyor and a second fiber separating machine;
8. the first glue mixing system; 9, a tail gas treatment device, 10, a powder winnowing machine, 11, a powder storage device, 12, a second metering conveyor and 13, a second glue mixing system;
14. the surface layer paving machine, the 15, the shaping conveyer, the 16, the weighing instrument, the 17, the core layer paving machine;
18. The second cyclone separating device, 19, the third cyclone separating device;
21. Preformer, 22, longitudinal edge saw, 23, plate loading conveyor, 24, flexible continuous press, 25, electric control system, 26, edge sawing machine, 27, density detector;
28. the polishing machine, 29, the surface detector, 30, sort the packaging system;
201. The device comprises a distributing device, a measuring bin, a 203, a second measuring belt, a 204, a second scattering roller, a 205, a paving box, a 206, a star cage roller, a 207 and a leveling roller;
208. A feeding belt; 209, a first metering belt, 210, a first dispersion roller, 211, a paving toothed roller;
301. Lower driven roller, 302, lower steel belt, 303, lower roller blanket, 304, frame group, 305, lower hot press plate, 306, inlet hot press plate, 307, upper hot press plate;
308. Oil cylinder, 309, lower driving roller, 310, upper driving roller, 311, upper steel belt, 312, upper roller blanket, 313, upper driven roller;
314. upper feed head 315, inlet lifting group 316, electric system 317, hydraulic system 318, heating system 319, plate blank 320, finished plate;
321. piston cylinder, 322 plunger cylinder.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required to be used in the embodiments will be briefly described below. It is apparent that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained from these drawings without inventive effort for a person of ordinary skill in the art.
The present invention will be described in detail below with reference to the drawings and the specific embodiments, which are not described in detail herein, but the embodiments of the present invention are not limited to the following embodiments.
Referring to fig. 1 to 10, the high-strength fiberboard production process of the present invention is realized based on a set of high-strength fiberboard production equipment including a flexible continuous press 24, the high-strength fiberboard production equipment including a raw material preparation section, a blank sizing section, a mat-forming section, a continuous press-forming section and a post-treatment finished product section.
The raw material preparation section comprises a defibrator 1, a classifying screen 2, a fiber air separator 3, a powder air separator 10, a first cyclone separation device 4, a second cyclone separation device 18, a fiber storage device 5, a powder storage device 11 and a tail gas treatment device 9. The fiber separating machine 1, the classifying screen 2, the fiber winnowing machine 3, the first cyclone separation device 4, the fiber storage device 5 and the tail gas treatment device 9 form a fiber blank preparation process section, and the fiber separating machine 1, the classifying screen 2, the powder winnowing machine 10, the second cyclone separation device 18, the powder storage device 11 and the tail gas treatment device 9 form a powder blank preparation process section.
The method comprises the steps of feeding a bundle of rock wool raw material bags into a defibrator 1 for defibration to form fiber bulk materials, screening the rock wool raw materials through a classifying screen 2 to obtain blanks with different classifications of fibers, powder and the like required by plate making, wherein the lengths, the shapes and the thicknesses of the fibers can be controlled according to the requirements of the screens, the classified fibers and the classified powder can be respectively winnowed through a fiber winnowing machine 3 and a powder winnowing machine 10 to obtain good materials and remove impurities, and then the fiber blanks and the powder blanks required by plate making are respectively fed into different fiber storage equipment 5 and powder storage equipment 11 through a pneumatic conveying and first cyclone separation device 4 and a second cyclone separation device 18.
The fiber storage device 5 is arranged at the lower end of the first cyclone separation device 4, the powder storage device 11 is arranged at the lower end of the second cyclone separation device 18, and the fiber blank and the powder blank after impurity removal and separation directly fall into the corresponding storage device.
The blank gluing section comprises a first metering conveyor 6, a second metering conveyor 12, a secondary fiber-breaking machine 7, a first glue mixing system 8 and a second glue mixing system 13. The first metering conveyor 6 is used to control the amount of raw material of the fibrous blank entering the first glue system 8 and likewise the second metering conveyor 12 is used to control the amount of raw material of the powder blank entering the second glue system 13.
The first metering conveyor 6 is arranged at the discharge end of the fiber storage device 5, and the secondary fiber-dissolving machine 7 is arranged between the first metering conveyor 6 and the first glue mixing system 8. The secondary fiber splitting machine 7 can be used for effectively scattering and scattering fiber blanks output in the fiber storage device 5, the problem that the fiber blanks are accumulated in the fiber storage device 5 is solved, the clustered fibers can be rapidly scattered and qualified fiber materials are conveyed to the first glue mixing system 8 through the effect of the secondary fiber splitting machine 7, the quality of a finished product plate 320 is improved, meanwhile, powder can be generated in the process of scattering the fiber blanks by the secondary fiber splitting machine 7, a powder discharge port of the powder discharging device is connected with the second glue mixing system 13 through the third cyclone separation device 19, the utilization rate of raw materials can be greatly improved, meanwhile, the residue of the powder in the fiber blanks can be reduced, and the quality of the finished product plate 320 is further improved.
Wherein, first cyclone 4, second cyclone 18 and third cyclone 19 all can produce tiny fine dust of rock and a small amount of fibre that raise in the use gets into tail gas processing apparatus along with the air current, ensures that tail gas emission granularity accords with national standard's environmental protection requirement, lets in same tail gas processing apparatus 9 with the tail gas of above three cyclone and carries out tail gas treatment, can reduce the holistic area of equipment.
The second metering conveyor 12 is arranged at the discharge end of the powder storage device 11, the second metering conveyor 12 is directly connected with the second glue mixing system 13, and glue mixing is carried out on the powder blanks fed by the third cyclone separation device 19 and the second glue mixing system 13.
The first glue mixing system 8 and the second glue mixing system 13 are basically same in structure and are provided with devices such as a meter, a reaction kettle and a material distributing conveyor, and the difference is that the first glue mixing system 8 and the second glue mixing system 13 are provided with different fiber sizing machines, namely the first glue mixing system 8 is provided with a fiber sizing machine, the second glue mixing system 13 is provided with a powder sizing machine, the fiber sizing machine adopts a roller sizing machine mode to mix fibers with proper glue powder, additives and the like to form a fiber glue mixture, the powder sizing machine adopts a stirring sizing machine mode to mix powder with proper glue powder, additives and the like to form a glue-containing powder blank, and before sizing, the glue-making raw materials are produced into the proper glue powder in the reaction kettle, and the blanks, the glue powder, the additives and the like are metered to required proportion values by the meter, and the glue mixture with proper proportion is prepared through the glue mixing system, and comprises the fiber glue mixture and the powder glue mixture. The adhesive powder is composed of phenolic resin, urea-formaldehyde resin, carbon dioxide-accumulating resin, polyester resin, etc., preferably phenolic resin and carbon dioxide-accumulating resin, and can be added with a small amount of thermoplastic composite material, the moisture content of the dry adhesive powder is low, abnormal conditions such as board explosion and bubbling in the hot pressing process are avoided, the raw material of the adhesive powder is not limited in scope under the specific process requirement, and a proper water-based adhesive can be adopted, and the hot pressing process is adjusted in time.
The mat-laying forming section comprises a forming conveyor 15, a plurality of skin-laying machines 14 and at least one core-laying machine 17 arranged along the forming conveyor 15. Wherein the surface layer paving machine 14 is used for paving the powder and rubber mixture on the belt of the forming conveyor 15 to form the surface layer of the finished board 320, and the core layer paving machine 17 is used for paving the fiber and rubber mixture on the powder and rubber mixture to form the core layer of the finished board 320. The arrangement of the core layer spreader 17 and the skin layer spreader 14 is determined based on the layer structure of the finished board 320, and if the finished board 320 has a three-layer structure, the first spreader is set as the skin layer spreader 14, the second is set as the core layer spreader 17, and the third is set as the skin layer spreader 14, and the first spreader refers to the first spreader located at the head end of the forming conveyor 15, that is, the spreader farthest from the flexible continuous press 24. The first and last pavers are skin pavers 14, the first for laying the lower skin of the finished board 320, the last for laying the upper skin of the finished board 320, and the middle may be provided with skin pavers 14 and core pavers 17 based on the board structure.
The surface layer paving machine 14 is similar to wood-based board paving machine equipment and comprises a feeding belt 208, a first metering belt 209, a first dispersing roller 210 and a paving toothed roller 211, wherein part of powder is distributed on the lower surface layer through the first metering belt 209, the first dispersing roller 210 and the paving toothed roller 211. The specific process of the surface layer paving machine 14 is that the feeding hole of the surface layer paving machine 14 is funnel-shaped, the feeding belt 208 is positioned right below the feeding hole, the powder and glue mixture falls into the feeding belt 208 after passing through the feeding hole, a plurality of first scattering rollers 210 are arranged at the tail end of the feeding belt 208, the plurality of first scattering rollers 210 are downwards arranged in a staggered mode along the feeding direction of the feeding belt 208, namely, a certain angle exists between a connecting line of the rotation centers of the plurality of first scattering rollers 210 and the feeding belt 208, the length of the first metering belt 209 is not smaller than the sum of the projection lengths of the feeding belt 208 and the plurality of first scattering rollers 210 in the feeding direction so as to prevent the powder and glue mixture from falling into an ineffective area of the surface layer paving machine 14, and a plurality of paving toothed rollers 211 are arranged below the first metering belt 209, preferably, are arranged from the tail end of the first metering belt 209 and have overlapping parts with the first metering belt 209.
The core layer paving machine 17 comprises a distributing device 201, a metering bin 202, a second metering belt 203, a plurality of second scattering rollers 204, a paving box 205, a plurality of multi-layer star-cage rollers 206 and a plurality of leveling rollers 207, wherein the second scattering rollers 204 and the multi-layer star-cage rollers 206 are used for evenly paving fiber materials on surface layer slabs, and the leveling rollers 207 are used for controlling the heights and the surface quality of the slabs. The measuring bin 202 is internally provided with a second measuring belt 203 and a plurality of second scattering rollers 204 positioned above the second measuring belt 203, a paving box 205 is arranged below the measuring bin 202, the paving box 205 and the measuring bin 202 are arranged in a staggered mode in the conveying direction box of the forming conveyor 15, a plurality of layers of star cage rollers 206 and a plurality of leveling rollers 207 are arranged in the paving box 205, wherein the layers of star cage rollers 206 are arranged on one side close to the measuring bin 202, and the plurality of leveling rollers 207 are arranged on one side of the measuring bin 202. The core layer paving machine 17 has the specific flow that a feed inlet of the core layer paving machine 17 is directly connected with a distributing device 201, a discharge outlet of the distributing device 201 is in a funnel shape, the distributing device 201 is used for primarily scattering material groups and separating a small amount of glue groups generated in a sizing system, waste disposal of glue groups is carried out, a fiber glue mixture enters a metering bin 202 after passing through the distributing device 201, a plurality of second scattering rollers 204 are downwards arranged along the feeding direction of a second metering belt 203 in a staggered manner, namely, a certain angle exists between a connecting line of the rotation centers of the plurality of second scattering rollers 204 and the second metering belt 203, the fiber glue mixture is evenly paved on a lower surface layer slab under the action of a plurality of second scattering rollers 204 and a plurality of layers of star cage rollers 206, and the height and the surface quality of the slab are controlled under the action of a leveling roller 207.
The first scattering roller 210 and the second scattering roller 204 are in a knife roller shape, the star cage roller 206 is a cage roller with slender rods distributed circumferentially, the problem that rock wool fiber materials are too long to be scattered can be effectively solved, and the star cage roller 206 is arranged in multiple layers, so that scattering of the fiber-rubber mixture is facilitated, and paving uniformity of the fiber-rubber mixture is guaranteed.
The fiber-rubber mixture is distributed on the middle core layer, the powder-rubber mixture is arranged on the surface layer, the fiber-rubber mixture and the powder-rubber mixture are distributed according to any combination of the process, the thickness ratio of blanks of the plate blank 319 is different, the performances of finished products are slightly different, the surface layer paving machine 14 and the core layer paving machine 17 are used for accurately and hierarchically distributing the blanks on the belt of the lower forming conveyor 15 according to the numerical control ratio to form fluffy plate blanks 319, then the fluffy plate blanks 319 are subjected to air exhausting and pre-pressing forming through the pre-pressing machine 21, the plate blank height is obviously reduced to form plate blanks with primary binding force, the subsequent material conveying can be realized, and the two side edges of the plate blanks 319 are repaired neatly through the longitudinal edge saw 22.
The continuous press section comprises a plate conveyor 23, a flexible continuous press 24, an electrical control system 25.
The plate loading conveyor 23 sends the pre-pressed plate blank 319 to the lower steel belt 302 at the front end of the flexible continuous press 24, the pre-pressed plate blank 319 enters between the upper hot pressing plate 307 and the lower hot pressing plate 305 with the action of the specific temperature and pressure oil cylinders 308 under the clamping of the upper steel belt 311 and the lower steel belt 302, wherein the upper steel belt 311 and the lower steel belt 302 are circulating steel belts, a plurality of oil cylinders 308 with different diameters are arranged on the upper surface of the upper hot pressing plate 307 in an array, different displacement values and pressure values are set on the distance between the upper hot pressing plate 307 and the lower hot pressing plate 305 according to a process curve, and the pre-pressed plate blank 319 is transported along with the operation of the upper steel belt 311 and the lower steel belt 302, so that the heating and pressing process is completed, the plate blank 320 with certain physical property requirements is pressed and is conveyed to the next equipment through a plate discharging roller table.
Wherein flexible continuous press 24 comprises lower driven roll 301, lower steel strip 302, lower roll blanket 303, frame set 304, lower heated platen 305, inlet heated platen 306, upper heated platen 307, cylinder 308, lower drive roller 309, upper drive roller 310, upper steel strip 311, upper roll blanket 312, upper driven roll 313, upper feed head 314, inlet lifting set 315, electrical system 316, hydraulic system 317, heating system 318; at the inlet of the flexible continuous press 24, the front section of the upper hot pressing plate 307 is an inlet hot pressing plate 306 with thinner thickness, and the inlet hot pressing plate 306 is bent into curved surfaces with different radians according to the plate making process requirements so as to adapt to the smooth entering of plate blanks 319 (plate blanks with finished prepressing) with different types (including paving thickness, materials, pre-compactness, moisture content, adhesives and the like), ensure that the upper steel strip 311 and the lower steel strip 302 simultaneously contact the surface of the plate blank 319 (plate blanks with finished prepressing), realize the simultaneous heating and uniform exhaust of the plate blank 319, avoid the defects of wave, blank breakage, dust spots and the like, and also be beneficial to improving the bonding force of the surface layer of the plate blank; in the middle section, the upper hot-pressing plate 307, the lower hot-pressing plate 305, the upper roller blanket 312, the lower roller blanket 303, the upper steel belt 311 and the lower steel belt 302 form a working section of the pressing process of the plate blank 319, in the production process, the upper hot-pressing plate and the inlet hot-pressing plate 306 of the working section are in a micro-flexible wave curve state in the longitudinal direction (by adjusting the displacement of the extending end of the oil cylinder 308 in the longitudinal direction in the oil cylinder array) and in a concave arc state in the transverse direction (likewise, by adjusting the displacement of the extending end of the oil cylinder 308 in the transverse direction in the oil cylinder array) by adjusting the pressure of each oil cylinder 308 and the displacement of the extending end of the oil cylinder 308, thereby being beneficial to the exhaust and quality adjustment of the plate blank 319 in the heating and pressing process, and the length of the hot-pressing plate, the number of the oil cylinders 308 can be randomly combined in the longitudinal direction, so that the bottleneck of improving the speed and the productivity of common equipment is broken, and the production efficiency is improved.
For a plurality of oil cylinders 308 arranged in an array, a setting mode shown in fig. 5 is adopted, all the piston oil cylinders 321 are arranged on the inlet hot pressing plate 306, so that the inlet hot pressing plate 306 is bent into curved surfaces with different radians according to the requirements of a plate manufacturing process, the piston oil cylinders 321 are arranged on the two sides and the middle of the upper hot pressing plate 307, the plunger oil cylinders are arranged in the middle of the upper hot pressing plate 307, so that the upper hot pressing plate 307 can be transversely pulled into a concave arc-shaped state, the exhaust and quality adjustment of the plate blank 319 in the process of being heated and pressed are facilitated, in addition, in the longitudinal length direction, the oil cylinder size can be increased or decreased by arranging different oil cylinder diameters according to the requirements of the production process pressure, and the use quantity can be increased or decreased in the length direction, so that the production capacity of equipment can be adjusted according to the requirements.
Further, the invention adopts the complete equipment of the flexible continuous press 24 to carry out hot press molding on the rock wool fibers, the hot press temperature is usually 180-260 ℃, the surface pressure is 200-600N/cm < 2 >, the hot press process is a specific hot press process comprising high-pressure exhaust heat transfer, medium-pressure heat preservation solidification, low-pressure thickness fixing and pressure relief heat dissipation in sequence, the hot press process parameters of the plate making and heat dissipation such as the pressurization time, the pressure, the displacement, the temperature and the like are regulated to the required formula numerical value by adopting an electric PID closed-loop control system (P is proportional control, I is integral control and D is differential control) in combination with the displacement, the electric control automation degree is high, and the pressure and the temperature are not limited in the range and can be properly regulated under the specific process requirements. The electrical PID closed-loop control system of the hot pressing process of the plate mainly applies a PID electrical control algorithm of a PLC central control system to output control values and instructions to an actuating mechanism, namely displacement, pressure, temperature and speed of a flexible continuous press 24, height of a leveling roller 207 of a spreading machine, metering belt speed and the like, so that passive objects such as thickness, weight and the like of a plate blank 319 are in a required range, the passive objects are measured by a weighing instrument 16 and a density detector 27, and related mechanical property detection such as strength, nail holding force and the like is carried out, real-time actual values such as density, strength and the like are fed back to the PLC central control system, and the electrical control algorithm automatically corrects the values to form PID closed-loop control, thereby achieving the required reasonable plate quality target.
The post-processing finished product section comprises a trimming saw 26, a density detector 27, a sander 28, a surface detector 29 and a sorting and packing machine system. The specific process of post-processing the finished product section comprises the steps of cutting edges on two sides of the pressed rock fiber board through a cutting edge saw 26, sawing the continuous board into single boards with required length, distinguishing whether the single boards are qualified or not through a density detector 27, feeding the data back to an electric PID closed-loop control system of a press through the density detector 27 in real time, further adjusting various data values of a hot pressing production process in real time to ensure the qualification rate of the finished product, feeding the single boards into a sanding machine 28 for surface sanding polishing treatment, detecting the surface quality of the board through a surface detector 29, sorting, grading, stacking and packaging through a sorting and packaging system 30, and forming to form the finished product of the high-strength rock fiber board meeting the requirements, wherein the standard size and the quality are complete.
The flexible continuous press 24 is adopted in the application, the thickness deviation of the high-strength rock fiber board produced by the steps is less than 0.1mm, the average density is 900-1400kg/m 3, the static bending strength is not less than 25MPa, the elastic modulus is not less than 4000MPa, the surface bonding strength is not less than 1.2MPa, the board holding screw force is not less than 30KN, the water absorption thickness expansion rate is not more than 4% in 24 hours, and the high-strength rock fiber board has the properties of high strength, heat resistance, water resistance, small heat conductivity coefficient, heat preservation and the like, and can be directly applied to the fields of home decoration, construction, industry and the like as a special purpose board such as a heat insulation board, a flame retardant floor board, a curtain wallboard and the like.
According to the production process of the high-strength rock fiber board adopting the flexible continuous press 24 complete equipment, the rock cotton fibers are processed and pressed into the high-strength rock fiber board, so that the strength, the bearing capacity, the stability and the durability of the rock fiber board are improved. The rock wool fiber pressing plate process is completed by adopting a specific continuous heating and pressurizing mode of the flexible continuous press 24, the vertical displacement position of the hot pressing plate of the flexible continuous press 24 can be accurately positioned, the hot pressing temperatures and pressures at different positions in the production direction (or longitudinal direction) are set according to the production process requirements of the rock wool plate, and the plate hot pressing process parameters such as the production pressurizing time, temperature, pressure, displacement and the like are regulated by adopting an electric PID closed-loop control, so that one-key operation is realized, the equipment automation degree is high, the production quality is stable, and meanwhile, the intelligent manufacturing and the development main stream of energy conservation and carbon reduction can be responded.
Further, the high-strength rock fiber board production process adopting the flexible continuous press 24 complete equipment can also adopt a gap type multi-layer press or a single-layer press or a synchronous lifting continuous press or a flexible continuous press 24, and the flexible continuous press 24 is adopted to produce the high-quality high-yield high-energy-consumption low-cost stable-performance high-performance flexible continuous press 24.
The production process of the high-strength rock fiber board adopting the flexible continuous press 24 complete equipment can be widely applied to the treatment of industrial solid wastes such as basalt fiber-making slag, steel smelting slag, coal gangue slag and the like to be pressed into a regenerated artificial board, but raw material pretreatment equipment such as crushing, high-temperature treatment, centrifugation and the like is required to be added to press the industrial solid wastes into the regenerated artificial board, so that good economic benefit and social benefit can be brought.
The above description is only of embodiments of the present invention and is not intended to limit the present invention, and various modifications and variations of the present invention will be apparent to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
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