JPH0437214B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to an improvement in a mineral fiber sound-absorbing ceiling material that hardly sags when absorbing moisture and has excellent sound-absorbing properties.

(Conventional technology and its problems) Ceiling material A made of fiberboard made from mineral fiberboard such as rock wool has been used in buildings and other places due to its excellent heat insulation, fireproofing, and sound absorption properties. It is widely used as ceiling material A of buildings.

However, ceiling material A made of mineral fiberboard uses a binder mainly made of starch, which can achieve a large bonding effect with a small amount of addition, so it has a drawback in terms of moisture resistance, and large-sized ceilings If it is formed on material A, it is likely that the central part will sag due to its own weight as it absorbs moisture, especially when using the drop-in method.
When the ceiling material A was constructed and supported between the shaped bars 4, there was a drawback that a large sag occurred because the central portion was not supported in any way.

In order to eliminate such drawbacks, it has been proposed that the entire ceiling material body 1 is impregnated with a highly water-resistant binder such as phenolic resin, or that a thin layer of resin is directly applied to the back surface 2 of the ceiling material body 1. Ta.

However, in the case of the former, the main problem is that since the entire ceiling material A is hardened with resin, when the ceiling material A is installed on the ceiling, it hardens to the surface side of the ceiling material A, resulting in poor sound absorption and the tendency to generate echoes. In the latter case, the resin coating layer 5 shrinks during drying and the entire ceiling material A warps, and when moisture is absorbed, the thin coating layer 5 is insufficient to prevent sag. It has the disadvantage that it does not exhibit strength and sag occurs, and in any case, it has not been possible to prevent sag that is sufficiently satisfactory in terms of appearance.

(Objective of the present invention) The present invention was made in view of the drawbacks of the conventional examples, and its purpose is to exhibit good sound absorption properties and at the same time prevent the occurrence of sagging due to its own weight even indoors in a high humidity environment. To provide a mineral fiber sound-absorbing ceiling material that can prevent sound as much as possible.

(Means for Solving the Problems) In order to achieve the above-mentioned object, the present invention aims to increase the thickness of the ceiling material body 1 made of mineral fibers by 10 to 50 mm from the back surface 2 of the ceiling material body 1 toward the inside. A technical measure is adopted in which the impregnated layer 3 of thermosetting resin is made up to a depth of 50%.

(Function) A sound-absorbing ceiling material A is installed between T-shaped bars 4 suspended from the ceiling with the thermosetting resin impregnated layer 3 facing the back surface 2.

Moisture in the room is gradually absorbed by the sound-absorbing ceiling material A and penetrates into the interior.As a result, although the strength of the binder contained on the front side of the ceiling material A decreases to some extent when moisture is absorbed, the resin on the back side 2 Since the impregnated layer 3 has a certain thickness, no decrease in strength due to moisture absorption is observed, and the occurrence of sag is suppressed to a small amount.

At the same time, the surface side of sound-absorbing ceiling material A is resin-impregnated layer 3.
Since it remains a porous fiber layer, the sound absorbing material is not damaged.

(Example) Hereinafter, the present invention will be described in detail according to illustrated examples.
The mineral fiber used in the present invention is mainly rock wool, and the following description will focus on rock wool. First, wet mat B is formed by kneading and forming rock wool with other materials such as a binder, a thickener, a filler, and water. Next, apply thermosetting resin from the top of wet mat B to 10 to 50 mm of the entire board thickness.
% to form a resin-impregnated layer 3. The resin used is, for example, a melamine resin emulsion, and the resin addition rate is preferably in the range of 1 to 10% in terms of resin solid content based on the total dry weight of the rock wool mat B. That is, if the addition rate is too low, the hardness of the resin-impregnated layer 3 will be insufficient, and if the addition rate is too high, the hardness will be excessive, causing the ceiling material A to warp.
The resin impregnation into the rock wool mat B may be carried out after the mat has been dried, but it is preferable to impregnate the mat in a wet state since the resin liquid can permeate uniformly and smoothly. When the resin impregnation is completed, a drying process begins, in which the entire rock wool mat B is dried and at the same time, the resin-impregnated layer 3 is cured. When the drying process is completed, the rock wool mat B is turned over so that the non-impregnated surface faces upward, and the non-impregnated surface is smoothed by sanding, painted, and decorated as appropriate, such as with a pin hole pattern 6, to complete the sound-absorbing ceiling material A. let

Thus, the sound-absorbing ceiling material A is installed between the T-shaped bars 4 suspended from the ceiling with the thermosetting resin impregnated layer 3 facing the back surface 2. Then, the moisture in the room is gradually absorbed by the sound-absorbing ceiling material A, and although the strength of the binder on the front side of the ceiling material A decreases to some extent during moisture absorption, the resin-impregnated layer 3 on the back side 2 maintains a certain thickness. Because of this, no decrease in strength due to moisture absorption is observed, and sag generation is suppressed to a small amount. At the same time, the surface side of the sound-absorbing ceiling material A is not formed into the resin-impregnated layer 3, but remains a porous fiber layer, so sounds with various frequencies and intensities generated in the room are absorbed by the fiber layer. , sound absorption properties are not impaired.

(Example 1) A sound-absorbing ceiling material A with a thickness of 5/8 inches, a width of 24 inches, and a length of 48 inches was installed between 4 T-shaped bars and heated at 30℃90
The sag value of ceiling material A was measured after one week of ceiling construction in a room under an environment of %RH. The results are shown in FIG.

When ceiling material A is impregnated with thermosetting resin, the sag value decreases, but the impregnated layer 3 is 10 to 10 times the thickness of ceiling material A.
The sag value shows almost the lowest value in the range up to 50% depth (in particular, the minimum value is shown around 30% depth), and thereafter increases as the impregnated layer 3 increases. In addition, as the addition rate of the thermosetting resin increases, the sag value decreases, but if the addition rate is too high, the hardness of the impregnated layer 3 becomes too high, which causes the ceiling material A to warp, and the sag value increases up to 10. It is about %. Therefore, in practice, the impregnated layer 3 should be 10 to 50% of the total thickness, and the thermosetting resin addition rate should be 1.
It will be limited to ~10%.

(Effects) As described above, the present invention reduces the thickness of the ceiling material body made of mineral fibers from the back side toward the inside.
Since the thermosetting resin is impregnated to a depth of 10 to 50%, even if it is installed between T-bars indoors in a high humidity environment and allowed to absorb moisture, the resin impregnated layer on the back side will remain to some extent. Because it is thick, there is almost no loss in strength and a significant improvement in sag can be achieved, and since the surface side remains a fiber layer, its sound absorption properties are not compromised, which is an advantage that conventional ceiling materials do not have. .

[Brief explanation of drawings]

Fig. 1a...Explanatory diagram of the manufacturing state of the conventional example, 1st
Figure b...Explanatory view of the manufacturing state of the present invention, Figure 2a...
...Cross-sectional view of a conventional example in which the entire ceiling material is impregnated with resin, Figure 2b...Cross-sectional view of a conventional example in which resin is applied to the back side of the ceiling material, Figure 2c...Resin is applied to the back side of the ceiling material. A sectional view of an example of the impregnated ceiling material of the present invention, FIG. 3...Graph showing experimental results of the ceiling material of the present invention A...Sound absorbing ceiling material, B...Wet mat, 1
... Ceiling material main body, 2... Back side of ceiling material, 3... Resin impregnated layer, 4... T-shaped bar, 5... Coating layer.

Claims (1)

[Scope of Claims] 1. A layer impregnated with a thermosetting resin from the back side of the ceiling material body made of mineral fibers to a depth of 10 to 50% of the thickness of the ceiling material body; Mineral fibers characterized in that the amount of resin impregnated is 1 to 10% by weight of the solid resin in the ceiling material body so that porous voids remain in the impregnated layer. Made of sound-absorbing ceiling material.