Production process of high-strength rock fiber board

Abstract

The invention relates to a high-strength rock fiber board production process which comprises the following steps: sequentially performing defibrating, screening and winnowing on bundled rock wool raw material bags to obtain a fiber blank and a powder blank required by board making; respectively mixing the fiber blank and the powder blank with corresponding rubber powder to obtain a fiber-rubber mixture and a powder-rubber mixture; feeding the powder and sizing material mixture and the fiber and sizing material mixture into a corresponding spreading machine, spreading according to the accurate metering of the materials, and pre-pressing and exhausting and forming in a pre-pressing machine, so as to obtain a plate blank with initial binding force; feeding the plate blank into a flexible continuous press for high-temperature and high-pressure pressing treatment to form a plate material; and carrying out edge cutting and saw cutting, surface sanding and polishing, sorting and packaging on the manufactured plate to form the high-strength rock fiber plate. The strength, the bearing capacity, the stability and the durability of the rock fiber board are improved.

Description

Technical Field

[0001] The invention relates to a production process of a high-strength rock fiber board. Background Art

[0002] At present, rock wool fiber, as an excellent inorganic fiber material, has good thermal insulation, flame retardant, non-toxic and environmentally friendly properties, and is widely used in construction, industry and other fields. However, the production method of rock fiber board is usually simple paving and hot pressing process, and the density of the finished product is mostly 60-200kg / m 3 , low strength, poor bearing capacity, stability and durability, daily use as filler or surface attached metal plate, increased construction difficulty and application cost, also affected the use effect; there is also a method of making wood density board, adding water-based adhesive to rock wool fiber, using air flow paving and gap press hot pressing molding, the density and strength of the finished product are greatly improved, but because of the high water content, fiber clusters are difficult to break up, and the hot pressing process often causes abnormalities or deficiencies such as bursting and bubbling, which affects the quality stability of the finished product and the high consumption of raw materials; there is also a method of making rock wool fiber There is a production method of spraying resin and heating to solidify it. However, due to the limitations of the glue application method and the pressurization pressure, the density uniformity and flatness deviation of the finished product are affected. There is also a production method of hot pressing rock wool fiber and silicate cement, which increases the density and reduces the cost. However, due to the low pressure and long pressure holding time, the toughness and surface bonding strength of the finished product are affected, and the production efficiency is low. There is also a rolling method using heated and pressurized rollers to make rock fiber boards. The equipment is simple, but because there is a temperature difference between the front and back sides of the roller surface when it is heated, and the roller surface pressure is high, it is easy to deform, affecting the thickness of the board surface and the density uniformity.

[0003] However, the common production methods of the above-mentioned rock fiber boards generally use intermittent multi-layer presses or single-layer presses or synchronous lifting continuous press equipment. The thickness, uniformity and strength performance of the finished boards are difficult to control, the surface bonding strength and the board surface screw holding force are low, the quality is greatly affected, and the production efficiency is also low. Summary of the invention

[0004] The object of the present invention is to provide a high-strength rock fiber board production process to improve the density, strength and product quality of the rock fiber board.

[0005] To achieve the above-mentioned object, the present invention provides a high-strength rock fiber board production process, which is implemented based on a set of high-strength rock fiber board production equipment including a flexible continuous press, and the high-strength rock fiber board production equipment includes a raw material preparation section, a blank gluing section, a slab paving and forming section, a continuous pressing section and a post-processing finished product section. The high-strength rock fiber board production process includes the following steps:

[0006] Step S1, in the raw material preparation section, the bundled rock wool raw material packages are successively defibrated, screened and air-selected to obtain fiber blanks and powder blanks required for board making;

[0007] Step S2, in the blank gluing section, mixing the fiber blank and the powder blank with corresponding rubber powders respectively to obtain a fiber-rubber mixture and a powder-rubber mixture;

[0008] Step S3, in the slab paving and forming section, the powder-rubber mixture and the fiber-rubber mixture are fed into the corresponding paving machine, paved according to the precise material measurement, and enter the pre-pressing machine for pre-pressing and exhaust molding to obtain a slab with preliminary bonding force;

[0009] Step S4, in the continuous pressing section, feeding the plate-making slab into a flexible continuous press for high-temperature and high-pressure pressing to form a plate-making plate;

[0010] Step S5: In the post-processing finished product section, the board material is trimmed and sawed, the surface is sanded and polished, and sorted and packaged to form a high-strength rock fiber board.

[0011] According to a technical solution of the present invention, the raw material preparation section includes a fiber disintegrator, a grading screen, a fiber air separator, a powder air separator, a first cyclone separator, a second cyclone separator, a fiber storage device and a powder storage device, and an exhaust gas treatment device;

[0012] The fiber disintegrator is used to disintegrate the bundled rock wool raw material packages to obtain rock fiber materials; the grading screen is used to screen the rock fiber materials to obtain fiber blanks and powder blanks required for board making; a conveyor belt is provided between the fiber disintegrator and the grading screen;

[0013] The fiber disintegrator, the grading screen, the fiber air separator, the first cyclone separation device, the fiber storage device and the tail gas treatment device constitute a fiber blank preparation process section;

[0014] The fiberizer, the grading screen, the powder air separator, the second cyclone separation device, the powder storage device and the tail gas treatment device constitute a powder blank preparation process section;

[0015] The first cyclone separation device and the second cyclone separation device are used for removing impurities and selecting materials;

[0016] 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.

[0017] According to a technical solution of the present invention, the billet glue application section includes a first metering conveyor, a second metering conveyor, a secondary defibrator, a first glue mixing system and a second glue mixing system;

[0018] The first metering conveyor is arranged at the discharge end of the fiber storage device, and the secondary defibrillator is arranged between the first metering conveyor and the first glue mixing system;

[0019] The second metering conveyor is arranged at the discharge end of the powder storage device, and the second metering conveyor is directly connected to the second glue mixing system;

[0020] The fiber outlet of the secondary defibrator is connected to the first glue conditioning system, and the powder outlet is connected to the second glue conditioning system through the third cyclone separation device;

[0021] The first cyclone separation device, the second cyclone separation device and the third cyclone separation device are all connected to the exhaust gas treatment device.

[0022] According to a technical solution of the present invention, the first glue mixing system and the second glue mixing system are both provided with a reaction kettle for preparing glue powder, and the first metering conveyor and the second metering conveyor are both composed of a meter and a material dividing conveyor;

[0023] The rubber powder is one or more of phenolic resin, urea-formaldehyde resin, polycarbonate resin or polyester resin;

[0024] The fiber-rubber mixture and the powder-rubber mixture are also mixed with oil thermoplastic composite materials.

[0025] According to a technical solution of the present invention, the slab paving and forming section includes a forming conveyor and a plurality of surface paving machines and at least one core layer paving machine arranged along the forming conveyor. The surface paving machines and the core layer paving machines distribute the blanks in layers on the belt of the forming conveyor below according to the proportion of numerical control to form fluffy slabs. The forming conveyor is equipped with a plurality of weighing instruments. A pre-pressing machine and a longitudinal edge saw are arranged at the end of the forming conveyor. The pre-pressing machine is used to exhaust and pre-press the fluffy slabs. The longitudinal edge saw is used to trim the side edges of the pre-pressed slabs.

[0026] Any of the surface paving machines described above comprises a feeding belt, a first metering belt, a first scattering roller, and a paving gear roller;

[0027] Any of the core layer paving machines comprises a material distribution device, a metering bin, a second metering belt, a plurality of second scattering rollers, a paving box, a multi-layer star cage roller, and a plurality of leveling rollers; the plurality of the second scattering rollers and the multi-layer star cage rollers are used to homogeneously pave the fiber material on the surface slab; the plurality of leveling rollers are used to control the height and surface quality of the slab;

[0028] The first scattering roller and the second scattering roller are in the shape of knife rollers, and the star cage roller is a cage-shaped roller with slender rods distributed around the circumference.

[0029] According to a technical solution of the present invention, the continuous pressing section includes a plate loading conveyor, the flexible continuous press, and an electric control system;

[0030] The plate loading conveyor is arranged between the flexible continuous press and the forming conveyor, and is used to deliver the pre-pressed plate blanks into the flexible continuous press;

[0031] The flexible continuous press is used to heat and pressurize the pre-pressed slab;

[0032] The electric control system is used to control the working parameters of the flexible continuous press.

[0033] According to a technical solution of the present invention, the flexible continuous press comprises a lower passive 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 driving roller, an upper steel belt, an upper roller blanket, an upper passive roller, an upper feed head, an inlet lifting group, an electrical system, a hydraulic system, and a heating system;

[0034] 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 constitute a slab pressing working section, and the slab pressing working section is arranged in the middle position of the flexible continuous press;

[0035] The plurality of oil cylinders are arranged in an array according to the pressure size on the upper surface of the upper hot pressing plate. By adjusting the pressure of each oil cylinder and the displacement of the extended end of the oil cylinder, the upper hot pressing plate of the working section is made into a slightly flexible wave curve state in the longitudinal direction and a concave arc state in the transverse direction.

[0036] According to a technical solution of the present invention, the slab pressing working section includes a high-pressure exhaust heat transfer section, a medium-pressure heat preservation and curing section, a low-pressure thickness setting section, and a pressure relief and heat dissipation section in sequence. The electric control system is an electric PID closed-loop control system, and the electric control system is used to adjust the hot pressing process parameters of the slab in any working section and the associated speed parameters and displacement parameters of the paving machine;

[0037] The plate making hot pressing process parameters at least include pressing time, pressure, displacement and temperature.

[0038] According to a technical solution of the present invention, the post-processing finished product section includes a trimming sawing machine, a density detector, a sanding machine, a surface detector, and a sorting and packaging machine system.

[0039] According to a technical solution of the present invention, the thickness deviation of the high-strength rock fiber board produced based on the steps S1 to S5 is less than 0.1 mm, and the average density is 900-1400 kg / m 3, static bending strength is not less than 25MPa, elastic modulus is not less than 4000MPa, surface bonding strength is not less than 1.2MPa, board surface screw holding force is not less than 30KN, and 24-hour water absorption thickness expansion rate is not more than 4%.

[0040] Compared with the prior art, the present invention has the following beneficial effects:

[0041] The present invention discloses a high-strength rock fiber board production process using a complete set of flexible continuous press equipment, which utilizes a complete set of high-strength rock fiber board production equipment including a flexible continuous press to process rock wool fibers. The whole set of equipment ultimately directly obtains high-strength rock fiber boards, thereby improving the strength, load-bearing capacity, stability and durability of the rock fiber boards.

[0042] The high-strength rock fiber board production process of the present invention is realized by utilizing a flexible continuous press, wherein the upper and lower displacement positions of the hot pressing plate can be accurately positioned to realize a flexible curved surface, and the hot pressing temperature and pressure at different positions in the production direction (or longitudinal direction) can be set according to the production process requirements, and the product quality of the pressed products is particularly improved. In addition, the production pressurizing time, temperature, pressure, displacement and other board making hot pressing process parameters are adjusted by an electrical PID closed-loop control system to obtain the required formula values, which has the advantages of high automation level, convenient operation, and easy control, and is conducive to improving production efficiency.

[0043] Furthermore, the multi-level paving structure of the surface paving machine and the core layer paving machine effectively improves the surface bonding strength of the rock fiber board and the board surface screw holding force, and the physical and mechanical properties of the finished board are excellent.

[0044] The high-strength rock fiber board produced by the high-strength rock fiber board production process of the present invention has a thickness deviation of less than 0.1 mm and an average density of 900-1400 kg / m 3 , static bending strength is not less than 25MPa, elastic modulus is not less than 4000MPa, surface bonding strength is not less than 1.2MPa, board surface screw holding force is not less than 30KN, and 24-hour water absorption thickness expansion rate is not more than 4%. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 A flow chart schematically showing a production process of a high-strength rock fiber board according to an embodiment of the present invention;

[0046] Figure 2 A schematic diagram of a process flow diagram of a complete set of equipment according to an embodiment of the present invention is schematically shown;

[0047] Figure 3 A schematic diagram schematically shows an equipment diagram of a core layer paving machine according to one embodiment of the present invention;

[0048] Figure 4A schematic diagram schematically showing an apparatus of a flexible continuous press according to one embodiment of the present invention;

[0049] Figure 5 A schematic diagram schematically showing the cylinder arrangement of a flexible continuous press according to an embodiment of the present invention;

[0050] Figure 6 A schematic diagram schematically shows a working state (longitudinal direction) of a hot pressing plate of a flexible continuous press according to one embodiment of the present invention;

[0051] Figure 7 A schematic diagram schematically shows a working state (horizontal) of a hot pressing plate of a flexible continuous press according to one embodiment of the present invention;

[0052] Figure 8 A schematic diagram of an electrical PID closed-loop control system according to an embodiment of the present invention is schematically shown;

[0053] Fig. 9 A schematic diagram schematically shows an equipment diagram of a surface paving machine according to one embodiment of the present invention;

[0054] Fig.10 Schematically showing an embodiment of the present invention Figure 4 An enlarged schematic diagram of point A.

[0055] in, Figures 1 to 10 The corresponding relationship between the reference numerals and the component names is as follows:

[0056] 1. Defibrating machine; 2. Classifying screen; 3. Fiber air separator; 4. First cyclone separation device; 5. Fiber storage device; 6. First metering conveyor; 7. Secondary defibrating machine;

[0057] 8. First glue mixing system; 9. Tail gas treatment device; 10. Powder air separator; 11. Powder storage device; 12. Second metering conveyor; 13. Second glue mixing system;

[0058] 14. Surface layer paving machine; 15. Forming conveyor; 16. Weighing instrument; 17. Core layer paving machine;

[0059] 18. Second cyclone separation device; 19. Third cyclone separation device;

[0060] 21. Pre-pressing machine; 22. Longitudinal edge saw; 23. Plate loading conveyor; 24. Flexible continuous press; 25. Electric control system; 26. Edge trimming saw; 27. Density detector;

[0061] 28. Sanding machine; 29. ​​Surface detector; 30. Sorting and packaging system;

[0062] 201, material dividing device; 202, metering bin; 203, second metering belt; 204, second scattering roller; 205, paving box; 206, star cage roller; 207, leveling roller;

[0063] 208, feeding belt; 209, first metering belt; 210, first scattering roller; 211, laying gear roller;

[0064] 301, lower passive roller; 302, lower steel belt; 303, lower roller blanket; 304, frame assembly; 305, lower hot pressing plate; 306, inlet hot pressing plate; 307, upper hot pressing plate;

[0065] 308, oil cylinder; 309, lower driving roller; 310, upper driving roller; 311, upper steel belt; 312, upper roller blanket; 313, upper passive roller;

[0066] 314, upper feed head; 315, entrance lifting group; 316, electrical system; 317, hydraulic system; 318, heating system; 319, slab; 320, finished plate;

[0067] 321, piston cylinder; 322, plunger cylinder. DETAILED DESCRIPTION

[0068] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention, and for ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0069] The present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments. The embodiments cannot be described one by one here, but the embodiments of the present invention are not therefore limited to the following embodiments.

[0070] See also Figures 1 to 10 The high-strength rock fiber board production process of the present invention is realized based on a set of high-strength rock fiber board production equipment including a flexible continuous press 24. The high-strength rock fiber board production equipment includes a raw material preparation section, a blank gluing section, a slab paving and forming section, a continuous pressing section and a post-processing finished product section.

[0071] The raw material preparation section includes a fiber disintegrator 1, a grading screen 2, a fiber air separator 3, a powder air separator 10, a first cyclone separator 4, a second cyclone separator 18, a fiber storage device 5 and a powder storage device 11, and an exhaust gas treatment device 9. The fiber disintegrator 1, the grading screen 2, the fiber air separator 3, the first cyclone separator 4, the fiber storage device 5 and the exhaust gas treatment device 9 constitute the fiber blank preparation process section; the fiber disintegrator 1, the grading screen 2, the powder air separator 10, the second cyclone separator 18, the powder storage device 11 and the exhaust gas treatment device 9 constitute the powder blank preparation process section.

[0072] The bundled rock wool raw material packages are sent to the defibrator 1 for defibration to form fiber bulk; the rock fiber material is screened through the grading screen 2 to obtain different graded blanks such as fibers and powders required for board making, wherein the length and shape of the fibers and the coarseness of the powders can be controlled as needed by the size of the screen; the graded fibers and powders are respectively air-selected by the fiber air separator 3 and the powder air separator 10 to select good materials and remove impurities; then, the fiber blanks and powder blanks required for board making are respectively sent to different fiber storage devices 5 and powder storage devices 11 through pneumatic conveying and the first cyclone separation device 4 and the second cyclone separation device 18.

[0073] Among them, the fiber storage device 5 is arranged at the lower end of the first cyclone separation device 4, and the powder storage device 11 is arranged at the lower end of the second cyclone separation device 18. The fiber blanks and powder blanks after impurity removal and separation directly fall into the corresponding storage devices.

[0074] The blank glue application section includes a first metering conveyor 6, a second metering conveyor 12, a secondary defibrator 7, a first glue adjustment system 8 and a second glue adjustment system 13. The first metering conveyor 6 is used to control the amount of raw materials of the fiber blank entering the first glue adjustment system 8, and similarly, the second metering conveyor 12 is used to control the amount of raw materials of the powder blank entering the second glue adjustment system 13.

[0075] The first metering conveyor 6 is arranged at the discharge end of the fiber storage device 5, and the secondary defibrillator 7 is arranged between the first metering conveyor 6 and the first glue adjustment system 8. The secondary defibrillator 7 can effectively break up the fiber blanks output from the fiber storage device 5, and can avoid the problem of the fiber blanks being accumulated in the fiber storage device 5. Through the action of the secondary defibrillator 7, the agglomerated fibers can be quickly broken up into qualified fiber materials and conveyed to the first glue adjustment system 8, thereby improving the quality of the finished board 320. At the same time, in the process of the secondary defibrillator 7 breaking up the fiber blanks, powder materials will be generated, and the powder material discharge port is connected to the second glue adjustment system 13 through the third cyclone separation device 19, which can greatly improve the utilization rate of raw materials, and at the same time can reduce the residual powder materials in the fiber blanks, further improving the quality of the finished board 320.

[0076] Among them, the first cyclone separation device 4, the second cyclone separation device 18 and the third cyclone separation device 19 will all generate fine rock fiber dust and a small amount of raised fibers during use, which will enter the exhaust gas treatment device along with the airflow, ensuring that the particle size of exhaust gas emissions meets the environmental protection requirements of national standards. The exhaust gases from the above three cyclone separation devices are passed into the same exhaust gas treatment device 9 for exhaust gas treatment, which can reduce the overall footprint of the equipment.

[0077] The second metering conveyor 12 is disposed at the discharge end of the powder storage device 11 . The second metering conveyor 12 is directly connected to the second glue mixing system 13 , and is mixed with the powder blanks fed into the third cyclone separation device 19 in the second glue mixing system 13 at the same time.

[0078] The structures of the first glue mixing system 8 and the second glue mixing system 13 are basically the same, and both are equipped with equipment such as meters, reactors, and material distribution conveyors. The difference is that the first glue mixing system 8 and the second glue mixing system 13 are equipped with different fiber glue applicators, that is, the first glue mixing system 8 is equipped with a fiber glue applicator, and the second glue mixing system 13 is equipped with a powder glue applicator; the fiber glue applicator adopts a roller glue applicator to mix the fiber with suitable glue powder, additives, etc. to form a fiber-glue mixture; the powder glue applicator adopts a stirring glue applicator to mix the powder with suitable glue powder, additives, etc. to form a powder blank containing glue; before gluing, the glue-making raw material produces suitable glue powder in the reactor, and the blank, glue powder, additives, etc. are measured to the required ratio by a meter, and a glue mixture with suitable proportions is made through the glue mixing system, including a fiber-glue mixture and a powder-glue mixture. The rubber powder includes phenolic resin, urea-formaldehyde resin, polycarbonate resin, polyester resin, etc., preferably phenolic resin and polycarbonate resin, and a small amount of thermoplastic composite material can also be added; the dry rubber powder has a low moisture content, which reduces abnormal conditions such as bursting and bubbling during the hot pressing process; under specific process requirements, the rubber powder raw materials are not limited to a range, and suitable water-based adhesives can also be used, and the hot pressing process should be adjusted in time.

[0079] The slab paving and forming section includes a forming conveyor 15 and a plurality of surface paving machines 14 and at least one core layer paving machine 17 arranged along the forming conveyor 15. The surface paving machine 14 is used to pave the powder-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 to pave the fiber-rubber mixture on the powder-rubber mixture to form the core layer of the finished board 320. The arrangement of the core layer paving machine 17 and the surface paving machine 14 is determined based on the layer structure of the finished board 320. If the finished board 320 is a three-layer structure, the first paving machine is set as the surface paving machine 14, the second is set as the core layer paving machine 17, and the third is set as the surface paving machine 14. The first paving machine refers to the first paving machine located at the head end of the forming conveyor 15, that is, the paving machine farthest from the flexible continuous press 24. The first paving machine and the last paving machine are both surface paving machines 14. The first paving machine is used to pave the lower surface layer of the finished board 320, and the last paving machine is used to pave the upper surface layer of the finished board 320. The middle paving machine can be set as a surface paving machine 14 and a core layer paving machine 17 based on the board layer structure.

[0080] The surface paving machine 14 is similar to a wood-based panel paving machine, including a feeding belt 208, a first metering belt 209, a first scattering roller 210, and a paving toothed roller 211. Part of the powder is distributed on the lower surface layer through the first metering belt 209, the first scattering roller 210, and the paving toothed roller 211. The specific process of the surface paving machine 14 is as follows: the feed port of the surface paving machine 14 is funnel-shaped, and the feeding belt 208 is located directly below the feed port. The powder-rubber mixture falls into the feeding belt 208 after passing through the feed port. A plurality of first scattering rollers 210 are arranged at the end of the feeding belt 208. The plurality of first scattering rollers 210 are arranged downward and staggered along the feeding direction of the feeding belt 208, that is, there is a certain angle between the line connecting 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 less than the sum of the projection lengths of the feeding belt 208 and the plurality of first scattering rollers 210 in the feeding direction to prevent the powder-rubber mixture from falling into the invalid area of ​​the surface paving machine 14. A plurality of paving toothed rollers 211 are arranged below the first metering belt 209. Preferably, they are arranged from the end of the first metering belt 209 and overlap with the first metering belt 209.

[0081] The core layer paving machine 17 includes a material dividing device 201, a metering bin 202, a second metering belt 203, multiple second scattering rollers 204, a paving box 205, a multi-layer star cage roller 206, and multiple leveling rollers 207; the multiple second scattering rollers 204 and the multi-layer star cage rollers 206 are used to evenly spread the fiber material on the surface slab; the multiple leveling rollers 207 are used to control the height and surface quality of the slab. A second metering belt 203 and a plurality of second breaking up rollers 204 located above the second metering belt 203 are arranged in the metering bin 202, a paving box 205 is arranged below the metering bin 202, the paving box 205 and the metering bin 202 are staggered in the transport direction of the forming conveyor 15, a multi-layer star cage roller 206 and a plurality of leveling rollers 207 are arranged in the paving box 205, wherein the multi-layer star cage roller 206 is arranged on the side close to the metering bin 202, and the plurality of leveling rollers 207 are arranged on one side of the metering bin 202. The specific process of the core layer paving machine 17 is as follows: the feed port of the core layer paving machine 17 is directly connected to the dividing device 201, and the discharge port of the dividing device 201 is funnel-shaped. The function of the dividing device 201 is to preliminarily break up the material agglomerates and separate the small amount of glue agglomerates produced in the gluing system, and discharge the glue agglomerates for waste treatment. After passing through the dividing device 201, the fiber-rubber mixture enters the metering bin 202. Similarly, multiple second breaking up rollers 204 are staggered downward and along the feeding direction of the second metering belt 203, that is, there is a certain angle between the line connecting the rotation centers of the multiple second breaking up rollers 204 and the second metering belt 203. Through the action of multiple second breaking up rollers 204 and multi-layer star cage rollers 206, the fiber-rubber mixture is evenly spread on the lower surface slab, and then the height and surface quality of the slab are controlled by the action of the leveling roller 207.

[0082] Among them, the rollers of the first scattering roller 210 and the second scattering roller 204 are in the shape of knife rollers, and the star cage roller 206 is a cage-shaped roller with slender rods distributed circumferentially, which can effectively solve the problem that the rock wool fiber material is too long and difficult to scatter. Moreover, the star cage roller 206 is arranged in multiple layers, which is conducive to the scattering of the fiber-rubber mixture and ensures the uniformity of the paving of the fiber-rubber mixture.

[0083] The fiber-rubber mixture is distributed in the middle core layer, and the powder-rubber mixture is arranged on the surface layer. The distribution of the fiber-rubber mixture and the powder-rubber mixture can be arbitrarily combined according to the process, but the performance of the finished product is slightly different due to the different coarseness ratio of the slab 319; the surface paving machine 14 and the core layer paving machine 17 both distribute the slabs in precise layers on the belt of the forming conveyor 15 below according to the CNC ratio to form a fluffy slab 319; thereafter, the fluffy slab 319 is vented and pre-pressed by the pre-pressing machine 21, and the height of the slab is significantly reduced, forming a slab with preliminary bonding force, which can realize subsequent material transportation; the edges of the slab 319 on both sides are trimmed neatly by the longitudinal edge saw 22.

[0084] The continuous pressing section includes a plate-loading conveyor 23 , a flexible continuous press 24 , and an electric control system 25 .

[0085] The plate loading conveyor 23 delivers the pre-pressed slab 319 onto the lower steel belt 302 at the front end of the flexible continuous press 24, and under the clamping of the upper steel belt 311 and the lower steel belt 302, it enters between the upper hot pressing plate 307 and the lower hot pressing plate 305 with the action of the oil cylinder 308 with specific temperature and pressure, wherein the upper steel belt 311 and the lower steel belt 302 are circulating steel belts, and a large number of oil cylinders 308 of different diameters are arranged in an array on the upper hot pressing plate 307, and the distance between the upper hot pressing plate 307 and the lower hot pressing plate 305 is set with different displacement values ​​and pressure values ​​according to the process curve; the pre-pressed slab 319 is transported along with the upper steel belt 311 and the lower steel belt 302, thereby completing the heating and pressing process, and is pressed into a finished plate 320 with certain physical property requirements, and is transported to the next equipment through the plate discharge roller table.

[0086] The flexible continuous press 24 includes a lower passive roller 301, a lower steel belt 302, a lower roller blanket 303, a frame group 304, a lower hot pressing plate 305, an inlet hot pressing plate 306, an upper hot pressing plate 307, a cylinder 308, a lower driving roller 309, an upper driving roller 310, an upper steel belt 311, an upper roller blanket 312, an upper passive roller 313, an upper feed head 314, an inlet lifting group 315, an electrical system 316, a hydraulic system 317, and a heating system 318; At the entrance of the press 24, the front section of the upper hot pressing plate 307 is the thinner entrance hot pressing plate 306, which is bent into curved surfaces of different curvatures according to the plate making process requirements to accommodate slabs 319 (pre-pressed slabs) of different types (including paving thickness, material, pre-density, moisture content, adhesive, etc.) to enter smoothly, and ensure that the upper steel belt 311 and the lower steel belt 302 contact the surface of the slab 319 (pre-pressed slab) at the same time, so as to achieve Heating and exhausting uniformly at the same time can avoid defects such as waves, broken billets, dust spots, etc., and it is also beneficial to improve the surface bonding force of the slab; 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 constitute the working section of the slab 319 pressing process. During the production process, by adjusting the pressure of each cylinder 308 and the displacement of the extended end of the cylinder 308, the upper hot plate and the inlet hot pressing plate 306 of the working section are made into a slightly flexible wave curve state in the longitudinal direction (by adjusting the displacement of the extended end of the cylinder 308 in the longitudinal direction of the cylinder array) and a concave arc state in the transverse direction (similarly, by adjusting the displacement of the extended end of the cylinder 308 in the transverse direction of the cylinder array), which is beneficial to the exhaust and quality adjustment of the slab 319 during the heating and pressing process; the length of the hot pressing plate and the number of cylinders 308 can be arbitrarily combined in the longitudinal direction, breaking the bottleneck of the common equipment speed and capacity improvement, and improving production efficiency.

[0087] For the plurality of oil cylinders 308 arranged in an array, the following method is used: Figure 5 In the arrangement shown, piston cylinders 321 are arranged throughout the inlet hot press plate 306 so that the inlet hot press plate 306 can be bent into curved surfaces of different curvatures according to the plate making process requirements to accommodate smooth entry of different types of slabs 319; piston cylinders 321 are arranged on both sides and in the middle of the upper hot press plate 307, and a plunger cylinder is arranged in the middle so that the upper hot press plate 307 can be pulled into a concave arc state in the horizontal direction, which is beneficial to the exhaust and quality adjustment of the slab 319 during the heating and pressing process; and in the longitudinal length direction, the cylinder size can be arranged with different cylinder diameters according to the production process pressure requirements, and the number of cylinders used can also be increased or decreased in the length direction to adjust the production capacity of the equipment as needed.

[0088] Furthermore, the present invention adopts a flexible continuous press 24 complete set of equipment to hot press the rock wool fiber into shape. The hot pressing temperature is usually 180-260°C, and the surface pressure is 200-600N / cm2. The hot pressing process is a specific hot pressing process consisting of high-pressure exhaust heat transfer, medium-pressure insulation and curing, low-pressure thickness setting, and pressure relief and heat dissipation. The plate making hot pressing process parameters such as pressing time, pressure, displacement, and temperature are adjusted to the required formula values ​​by combining the associated speed and displacement of the paving machine using an electrical PID closed-loop control system (P is proportional control, I is integral control, and D is differential control relationship). The electrical control has a high degree of automation. Under specific process requirements, the pressure and temperature are not limited to the range and can also be adjusted appropriately. The electrical PID closed-loop control system of the hot pressing process of plate making is mainly based on the control target of the quality target requirement of the plate making board, and applies the PID electrical control algorithm of the PLC central control system to output control values ​​and instructions to the actuator, that is, to control the displacement, pressure, temperature, speed of the flexible continuous press 24, and the height of the leveling roller 207 of the paving machine, the speed of the metering belt, etc., so that the passive objects such as the thickness and weight of the slab 319 are within the required range. The passive objects are then measured by the weighing instrument 16 and the density detector 27, as well as the relevant mechanical properties such as strength and nail holding force. The real-time actual values ​​of density, strength, etc. are fed back to the PLC central control system, and the electrical control algorithm automatically corrects the value to form a PID closed-loop control, thereby achieving the required reasonable quality target of the plate making board.

[0089] The post-processing finished product section includes a trimming saw 26, a density detector 27, a sanding machine 28, a surface detector 29, and a sorting and packaging machine system. The specific process of the post-processing finished product section is: the pressed rock fiber board is trimmed on both sides by the trimming saw 26, and the continuous board is sawed into a single board of the required length; the density detector 27 is used to distinguish whether the single board is qualified or not, and the density detector 27 will feed back the data to the electrical PID closed-loop control system of the press in real time, and then adjust the various data values ​​of the hot pressing production process in real time to ensure the qualified rate of the finished product; the single board is then sent to the sanding machine 28 for surface sanding and polishing, and the surface quality of the board is inspected by the surface detector 29; and then the sorting and packaging system 30 is used for classification, stacking, packaging and forming, forming a high-strength rock fiber board finished product with complete specifications and sizes and categories that meets the requirements.

[0090] In this application, a flexible continuous press 24 complete set of equipment is used, and the high-strength rock fiber board produced by the above steps has a thickness deviation of less than 0.1mm and an average density of 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 surface screw holding force is not less than 30KN, and the 24-hour water absorption thickness expansion rate is not more than 4%. It has the properties of high strength, heat resistance, waterproofness, low thermal conductivity, and thermal insulation. It can be used as special-purpose panels such as insulation panels, flame-retardant floors, curtain wall panels, and can be directly used in home decoration, construction, industry and other fields.

[0091] The present invention discloses a high-strength rock fiber board production process using a complete set of flexible continuous press 24 equipment, which processes rock wool fibers and presses them into high-strength rock fiber boards, thereby improving the strength, load-bearing capacity, stability and durability of the rock fiber boards. The rock wool fiber pressing board process is completed by using the specific continuous heating and pressurizing method of the flexible continuous press 24. The upper and lower displacement positions of the hot pressing plate of the flexible continuous press 24 can be accurately positioned. The hot pressing temperature and pressure at different positions in the production direction (or longitudinal direction) are set according to the rock fiber board production process requirements. The production pressurizing time, temperature, pressure, displacement and other board making hot pressing process parameters are adjusted by electrical PID closed-loop control to achieve one-button operation. The equipment has a high degree of automation and stable production quality. At the same time, it can also respond to the mainstream development of intelligent manufacturing and energy conservation and carbon reduction.

[0092] Furthermore, the high-strength rock fiberboard production process using a complete set of flexible continuous press 24 equipment can also be a gap-type multi-layer press or a single-layer press or a synchronous lifting continuous press or a flexible continuous press 24. The finished products produced by the flexible continuous press 24 have high quality, high output, low energy consumption, low cost and stable performance.

[0093] It should be noted that the high-strength rock fiber board production process of the present invention using a set of flexible continuous press 24 equipment can also be expanded to be used for pressing industrial solid waste such as basalt fiber making slag, steel smelting slag, coal gangue slag into recycled man-made boards. However, it is necessary to add raw material pretreatment equipment such as crushing, high-temperature treatment, and centrifugation. Pressing industrial solid waste into recycled man-made boards can also bring good economic and social benefits.

[0094] The above description is only an embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A high-strength rock fiber board production process, characterized in that: The high-strength rock fiber board production process is realized based on a complete set of high-strength rock fiber board production equipment including a flexible continuous press (24), the high-strength rock fiber board production equipment includes a raw material preparation section, a blank gluing section, a slab paving and forming section, a continuous pressing section and a post-processing finished product section, and the high-strength rock fiber board production process includes the following steps: Step S1, in the raw material preparation section, the bundled rock wool raw material packages are successively defibrated, screened and air-selected to obtain fiber blanks and powder blanks required for board making; Step S2, in the blank gluing section, mixing the fiber blank and the powder blank with corresponding rubber powders respectively to obtain a fiber-rubber mixture and a powder-rubber mixture; Step S3, in the slab paving and forming section, the powder-rubber mixture and the fiber-rubber mixture are fed into a corresponding paving machine, paved according to the precise material measurement, and enter a pre-pressing machine (21) for pre-pressing and exhaust molding to obtain a slab with preliminary bonding force; Step S4, in the continuous pressing section, feeding the plate-making slab into a flexible continuous press (24) for high-temperature and high-pressure pressing to form a plate-making plate; Step S5: In the post-processing finished product section, the board material is trimmed and sawed, the surface is sanded and polished, and sorted and packaged to form a high-strength rock fiber board.

2. The high-strength rock fiber board production process according to claim 1 is characterized in that: The raw material preparation section comprises a fiberizer (1), a grading 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 an exhaust gas treatment device (9); The fiber disintegrator (1) is used to disintegrate the bundled rock wool raw material packages to obtain rock fiber materials; the grading screen (2) is used to screen the rock fiber materials to obtain fiber blanks and powder blanks required for board making; a conveyor belt is provided between the fiber disintegrator (1) and the grading screen (2); The fiber disintegrator (1), the grading screen (2), the fiber air separator (3), the first cyclone separation device (4), the fiber storage device (5) and the tail gas treatment device (9) constitute a fiber blank preparation process section; The defibrating machine (1), the grading screen (2), the powder air separator (10), the second cyclone separation device (18), the powder storage device (11) and the tail gas treatment device (9) constitute a powder blank preparation process section; The first cyclone separation device (4) and the second cyclone separation device (18) are used for removing impurities and selecting materials; The fiber storage device (5) is arranged at the lower end of the first cyclone separation device (4), and the powder storage device (11) is arranged at the lower end of the second cyclone separation device (18).

3. The high-strength rock fiber board production process according to claim 2 is characterized in that: The blank glue application section comprises a first metering conveyor (6), a second metering conveyor (12), a secondary defibrator (7), a first glue mixing system (8) and a second glue mixing system (13); The first metering conveyor (6) is arranged at the discharge end of the fiber storage device (5), and the secondary defibrillator (7) is arranged between the first metering conveyor (6) and the first glue mixing system (8); The second metering conveyor (12) is arranged at the discharge end of the powder storage device (11), and the second metering conveyor (12) is directly connected to the second glue mixing system (13); The fiber discharge port of the secondary defibrator (7) is connected to the first glue conditioning system (8), and the powder discharge port is connected to the second glue conditioning system (13) via a third cyclone separation device (19); The first cyclone separation device (4), the second cyclone separation device (18) and the third cyclone separation device (19) are all connected to the exhaust gas treatment device (9).

4. The high-strength rock fiber board production process according to claim 3 is characterized in that: The first glue mixing system (8) and the second glue mixing system (13) are both provided with a reaction kettle for preparing glue powder, and the first metering conveyor (6) and the second metering conveyor (12) are both composed of a meter and a material dividing conveyor; The rubber powder is one or more of phenolic resin, urea-formaldehyde resin, polycarbonate resin or polyester resin; The fiber-rubber mixture and the powder-rubber mixture are also mixed with oil thermoplastic composite materials.

5. The high-strength rock fiber board production process according to claim 3 is characterized in that: The slab paving and forming section comprises a forming conveyor (15) and a plurality of surface paving machines (14) and at least one core layer paving machine (17) arranged along the forming conveyor (15); the surface paving machines (14) and the core layer paving machines (17) distribute the blanks in layers on the belt of the forming conveyor (15) below according to a numerically controlled ratio to form a fluffy slab (319); the forming conveyor (15) is equipped with a plurality of weighing instruments (16); a pre-pressing machine (21) and a longitudinal edge saw (22) are arranged at the end of the forming conveyor (15); the pre-pressing machine (21) is used to exhaust and pre-press the fluffy slab (319); the longitudinal edge saw (22) is used to trim the side of the pre-pressed slab (319); Any of the surface paving machines (14) comprises a feeding belt (208), a first metering belt (209), a first scattering roller (210), and a paving toothed roller (211); Any of the core layer paving machines (17) comprises a material distribution 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 star cage rollers (206), and a plurality of leveling rollers (207); the plurality of the second scattering rollers (204) and the plurality of star cage rollers (206) are used to uniformly pave the fiber material on the surface slab (319); the plurality of leveling rollers (207) are used to control the height and surface quality of the slab (319); The first scattering roller (210) and the second scattering roller (204) are in the shape of knife rollers, and the star cage roller (206) is a cage-shaped roller with slender rods distributed around the circumference.

6. The high-strength rock fiber board production process according to claim 5 is characterized in that: The continuous pressing section comprises a plate-loading conveyor (23), the flexible continuous press (24), and an electric control system (25); The loading conveyor (23) is arranged between the flexible continuous press (24) and the forming conveyor (15), and is used to convey the pre-pressed slab (319) into the flexible continuous press (24); The flexible continuous press (24) is used to heat and pressurize the pre-pressed slab (319); The electric control system (25) is used to control the working parameters of the flexible continuous press (24).

7. The high-strength rock fiber board production process according to claim 1 is characterized in that: The flexible continuous press (24) comprises a lower passive roller (301), a lower steel belt (302), a lower roller blanket (303), a frame group (304), a lower hot pressing plate (305), an inlet hot pressing plate (306), an upper hot pressing plate (307), an oil cylinder (308), a lower driving roller (309), an upper driving roller (310), an upper steel belt (311), an upper roller blanket (312), an upper passive roller (313), an upper feed head (314), an inlet lifting group (315), an electrical system (316), a hydraulic system (317), and a heating system (318); 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) constitute a slab (319) pressing working section, and the slab (319) pressing working section is arranged in the middle position of the flexible continuous press (24); The plurality of oil cylinders (308) are arranged in an array according to the pressure size on the upper surface of the upper hot pressing plate (307). By adjusting the pressure of each oil cylinder (308) and the displacement of the extended end of the oil cylinder (308), the upper hot pressing plate of the working section is formed into a slightly flexible wave curve state in the longitudinal direction and a concave arc state in the transverse direction.

8. The high-strength rock fiber board production process according to claim 6, characterized in that: The slab (319) pressing working section includes a high-pressure exhaust heat transfer section, a medium-pressure heat preservation and curing section, a low-pressure thickness setting section, and a pressure relief and heat dissipation section in sequence. The electric control system (25) is an electric PID closed-loop control system. The electric control system (25) is used to adjust the slab hot pressing process parameters of any working section and the associated speed parameters and displacement parameters of the paving machine. The plate making hot pressing process parameters at least include pressing time, pressure, displacement and temperature.

9. The high-strength rock fiber board production process according to claim 1, characterized in that: The post-processing finished product section includes a trimming sawing machine (26), a density detector (27), a sanding machine (28), a surface detector (29), and a sorting and packaging machine system.

10. The high-strength rock fiber board production process according to claim 1, characterized in that: The thickness deviation of the high-strength rock fiber board produced based on the steps S1 to S5 is less than 0.1 mm, and the average density is 900-1400 kg / m 3 , static bending strength is not less than 25MPa, elastic modulus is not less than 4000MPa, surface bonding strength is not less than 1.2MPa, board surface screw holding force is not less than 30KN, and 24-hour water absorption thickness expansion rate is not more than 4%.

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