Micro-perforated rock wool sound-absorbing board and its manufacturing method

Abstract

The present invention addresses the problem of providing a method for manufacturing a rock wool sound-absorbing board that is easy to manufacture and has excellent sound absorption properties and design. The method includes the steps of forming rock wool, which is an artificial mineral fiber, into a plate shape to produce a rock wool substrate; applying a coating to the surface of the rock wool substrate; and a step of drilling a large number of fine sound-absorbing holes, each having a diameter of 0.3 to 2 mm and a depth of 0.5 to 5 mm, vertically and uniformly on the surface of the coated rock wool substrate. The numerous fine sound absorbing holes are formed using a press die in which drilling pins having shapes corresponding to the hole diameters and depths are embedded so as to correspond to the drilling positions of the fine sound absorbing holes.

Description

[Technical Field]

[0001] The present invention is a finely perforated rock wool sound absorbing board. and More specifically, the present invention relates to a method for manufacturing a finely perforated rock wool sound absorbing board having excellent sound absorbing performance and designability. and This relates to a manufacturing method of the above. [Background technology]

[0002] Rock wool is an artificial mineral fiber, also known as rock wool, made by melting blast furnace slag or basalt at high temperatures and blowing it into fibers using centrifugal force. This rock wool is formed into a board, painted, and then patterned to create rock wool sound-absorbing boards, which are used as ceiling finishing materials, etc. This rock-faced sound-absorbing board is one of the inexpensive building ceiling materials, and is a material that exhibits sound-absorbing properties in indoor spaces. In order to reduce initial construction costs, it is widely used in public facilities, cultural complexes, offices, etc.

[0003] Rock wool sound-absorbing boards are made by molding mineral fibers into boards, and the painted surface has been chipped off, giving them excellent sound absorption properties. However, if rock wool sound-absorbing boards are used as is, the chipped off paint will reveal the disordered rock wool pattern, not only making them look bad, but also increasing the risk of the rock wool peeling off over time. Therefore, the surface may be further painted, but in this case, the rock wool, which has sound-absorbing properties, will be blocked by the paint, and the sound-absorbing properties may be reduced. Repainting is generally not recommended, as this defeats the original purpose of sound-absorbing boards, which is to reduce reverberation time.

[0004] Furthermore, after painting, the surface of the rock-faced sound-absorbing board may be randomly formed with pits known as worm-eaten patterns or marble-derived travertine patterns by embossing with a roll coater like the cylinder of a music box, or by chipping. These pits increase the surface area of ​​the rock wool on the surface of the rock-faced sound-absorbing board, enhancing the sound-absorbing effect and reducing indoor echoes (reducing reverberation time), while also enhancing the design of the interior space of the building.

[0005] However, when conventional rock wool sound-absorbing panels with this irregularly textured travertine pattern are used as ceiling materials, the pattern formed by unevenly spaced holes of various sizes and shapes can partially impair the design of the interior space of a building. In such cases, the existing product has been coated with a surface paint to fill in the pattern, but this work is not only time-consuming, but also has the risk of the paint filling in the holes and reducing sound-absorbing performance. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2022-158500 [Patent Document 2] Patent No. 6228571 Summary of the Invention [Problem to be solved by the invention]

[0007] As mentioned above, the present invention was made in consideration of the fact that when conventional rock wool sound-absorbing boards are used as ceiling materials, the unevenly arranged recesses of various sizes and shapes can sometimes impair the design, and provides a rock wool sound-absorbing board with excellent sound absorption properties and design. and The object of the present invention is to provide a method for producing the above-mentioned compound. [Means for solving the problem]

[0008] The invention described in claim 1 to solve the above problem is: A step of forming rock wool, which is an artificial mineral fiber, into a plate shape to produce a rock wool substrate; applying a coating to the surface of the rock wool substrate; and a step of drilling a large number of fine sound-absorbing holes, each having a diameter of 0.3 to 2 mm and a depth of 0.5 to 5 mm, vertically and uniformly on the surface of the coated rock wool substrate. This is a method for manufacturing rock wool sound-absorbing boards, characterized in that the numerous fine sound-absorbing holes are drilled using a press mold in which drilling pins of shapes corresponding to the hole diameter and depth are implanted so as to correspond to the drilling positions of the fine sound-absorbing holes.

[0009] The invention described in claim 4 to solve the above problem is: This rock wool sound-absorbing board is made by forming rock wool, an artificial mineral fiber, into a plate and coating the surface of the rock wool substrate, on whose surface a large number of fine sound-absorbing holes, each 0.3 to 2 mm in diameter and 0.5 to 5 mm deep, are drilled vertically and at uniform intervals. The fine sound-absorbing holes are drilled at intervals of 3 to 10 mm vertically and horizontally. [Effects of the Invention]

[0010] The rock wool sound absorbing board according to the present invention has a large number of fine sound absorbing holes drilled vertically and at uniform intervals on its surface, with the fine sound absorbing holes having a diameter of 0.3 to 2 mm and a depth of 0.5 to 5 mm, and are usually drilled at intervals of 3 to 10 mm vertically and horizontally, so that the design is not noticeably impaired and the sound absorbing effect is still there, resulting in a rock wool sound absorbing board with excellent sound absorbing properties and design. According to the manufacturing method of the present invention, the fine sound-absorbing holes can be drilled in one go using a press mold in which drilling pins of shapes corresponding to the hole diameter and depth are implanted so as to correspond to the drilling positions of the fine sound-absorbing holes, thereby achieving good manufacturing efficiency. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a front view showing a rock wool sound-absorbing board manufactured by the method for manufacturing a rock wool sound-absorbing board according to the present invention. FIG. [Figure 2] 1 is a diagram showing the configuration of a press mold used in a method for manufacturing a rock wool sound-absorbing board according to the present invention. FIG. [Figure 3] FIG. 2 is a vertical cross-sectional view showing the detailed configuration of a press mold used in the method for manufacturing a rock wool sound-absorbing board according to the present invention. [Figure 4] 1 is a plan view showing a method for manufacturing a rock wool sound-absorbing board according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0012] An embodiment of the present invention will be described in detail with reference to the accompanying drawings. A rock wool sound-absorbing board 1 manufactured by the manufacturing method of the present invention is a rock wool substrate 2 made by forming rock wool, an artificial mineral fiber, into a plate and applying a surface coating, on the surface of which a large number of fine sound-absorbing holes 3, each 0.3 to 2 mm in diameter and 0.5 to 5 mm deep, are drilled vertically and at uniform intervals. Preferably, the thickness of the rock wool substrate 2 is 9 to 15 mm, and the fine sound-absorbing holes 3 are drilled at intervals of 3 to 10 mm vertically and horizontally. In the example shown in Figure 1, the holes are drilled at intervals of 4 mm vertically and horizontally. The rock wool sound-absorbing board 1 can be manufactured to any size.

[0013] Typical rock wool sound-absorbing boards are made by melting blast furnace slag or basalt at high temperatures, blowing it away using centrifugal force to form fibrous rock wool, which is then dissolved in water to form a slurry (mixing process), and molded into a board using a method similar to papermaking (molding process).After cutting, the board is passed through a patterning roll that creates an uneven pattern on the outer surface to create a pattern (patterning process), and then painted and dried to form the finished product (finishing process).

[0014] The rock wool substrate 2 used in the method for manufacturing a rock wool sound absorbing board according to the present invention is manufactured by a method that shares the above-mentioned mixing step, molding step and finishing step, but does not include a patterning step using a patterning roll.

[0015] That is, the method for manufacturing the rock wool sound absorbing board 1 according to the present invention is as follows: - a step of forming rock wool, which is an artificial mineral fiber, into a plate shape to produce a rock wool substrate 2; - a step of applying a coating to the surface of the rock wool substrate 2; - A process of drilling a large number of fine sound-absorbing holes 3, each having a diameter of 0.3 to 2 mm and a depth of 0.5 to 5 mm, vertically and at equal intervals on the surface of the rock wool substrate 2 to which the coating has been applied, - All of the fine sound-absorbing holes 3 are drilled at once using a press die 11 in which drilling pins 12 having shapes corresponding to the hole diameters and depths are implanted so as to correspond to the arrangement of the fine sound-absorbing holes 3.

[0016] The reason why the hole diameter of the fine sound absorbing holes 3 is set to 0.3 to 2 mm is that it is actually difficult to drill holes with a diameter of 0.3 mm or less, and holes with a diameter of 2 mm or more are too noticeable and may impair the design. The reason why the depth is set to 0.5 to 5 mm is that if the hole is 0.5 mm or less, a sufficient sound absorbing effect cannot be obtained, and the reason why the depth is set to 5 mm or less is that if the hole is made deeper than that, there is not much difference in the sound absorbing effect.

[0017] The press die 11 is a so-called single-shot press die that performs press processing in one go after being set in the press. The press die 11 is sized to cover the rock wool substrate 2 to be drilled, and drilling pins 12 of a shape corresponding to the hole diameter and depth of the fine sound-absorbing holes 3 are implanted throughout its entire area at intervals corresponding to the spacing between the fine sound-absorbing holes 3.

[0018] 2 to 4 show an example of the configuration of a press die 11 used in a press machine for manufacturing rock wool sound-absorbing board 1 according to the present invention, and the basic configuration of the press machine is not particularly different from that of a general press machine. That is, it is configured to include an upper die set 15 which fixes and raises and lowers press die 11, which is the upper die, and a lower die set 17 which receives rock wool substrate 2, the workpiece, via a die plate 16 (see FIG. 2). A detailed description of the other components will be omitted. Note that press die 11 is a male die, and the processing performed by it is embossing (perforating micro sound-absorbing holes 3 with a depth of 0.5 to 5 mm and no corresponding female die exists, as the processing is not a punching process such as a punching process but an embossing process (perforating micro sound-absorbing holes 3 with a depth of 0.5 to 5 mm).

[0019] As described above, the press die 11 has a number of perforation pins 12 mounted on a die base 11a so as to protrude downward, and the perforation pins 12 have pins 12b protruding from the tips of cylindrical shafts 12a (see FIG. 3). For example, the upper ends of the cylindrical shafts 12a of the perforation pins 12 are made slightly larger in diameter so that a stepped portion of the shaft rests on a stepped portion of the larger diameter portion formed at the upper ends of insertion holes 11b of the perforation pins 12 that penetrate the die base 11a, thereby preventing the perforation pins 12 from slipping out downward. The upper die set 15 that supports the press die 11 is fixed on the die base 11a (see FIG. 2).

[0020] Stripper plates 21 are arranged at appropriate intervals below the press mold 11, which is fixed to the upper die set 15, and have loose insertion holes 20 formed therethrough, through which the downwardly projecting drilling pins 12 are loosely inserted (see Figure 3). The stripper plates 21 press down on the rock wool substrate 2 during drilling, thereby preventing the rock wool substrate 2 from deforming or shifting. The loose insertion holes 20 are made up of a large-diameter section corresponding to the cylindrical shaft 12a and a small-diameter section corresponding to the pins 12b, so as to correspond to the shape of the drilling pins 12, and the step at the bottom end of the cylindrical shaft 12a hits the step at the bottom end of the large-diameter section, thereby regulating the descending end of the pins 12b, in other words, the drilling depth of the fine sound-absorbing holes 3 (see Figure 3).

[0021] The manufacturing method according to the present invention is suitable for mass production of small lot products, since rock wool sound absorbing panels 1 with different numbers and positions of fine sound absorbing holes 3 can be manufactured by changing the number and arrangement of the drilling pins 12. In order to drill fine sound absorbing holes 3 with different hole diameters and / or depths, press dies 11 with drilling pins 12 of different sizes implanted therein may be prepared in advance.

[0022] If the rock wool sound-absorbing board 1 is small, the fine sound-absorbing holes 3 can be drilled all over the rock wool substrate 2 in one processing run, but for larger sizes, a method is used in which the rock wool substrate 2 is moved and shot multiple times. In this case, guide rails 22 are placed on both sides of the press mold 11 so as to extend forward and backward, and the rock wool substrate 2, supported on both sides by the guide rails 22, is processed while being moved manually or via a constant feed device (see Figure 4).

[0023] In the case of conventional perforation methods using a roll coater, the holes are slightly tilted and uneven, which looks bad and may impair the design. In contrast, the fine sound holes 3 in this invention are formed vertically and uniformly all over the rock wool substrate 2 at once by lowering a press die 11 from directly above onto the rock wool substrate 2, which is placed horizontally on a die plate 16, and pressing with a perforation pin 12. Therefore, unlike the conventional random moth holes (marble pattern) and uneven patterns, when installed as a ceiling material the holes are difficult to see and the design is excellent.

[0024] The rock wool sound-absorbing board according to the present invention is manufactured by the above-mentioned method for manufacturing a rock wool sound-absorbing board, and is characterized in that it is made by forming rock wool, which is an artificial mineral fiber, into a plate shape, applying a coating to the surface of the rock wool substrate, and then drilling a large number of fine sound-absorbing holes, each having a diameter of 0.3 to 2 mm and a depth of 0.5 to 5 mm, vertically and at uniform intervals. In a preferred embodiment, the fine sound-absorbing holes are drilled at intervals of 3 to 10 mm vertically and horizontally. [Industrial Applicability]

[0025] The rock wool sound absorbing board of the present invention has a large number of fine sound absorbing holes drilled vertically and at uniform intervals on its surface, and the fine sound absorbing holes have a diameter of 0.3 to 2 mm and a depth of 0.5 to 5 mm, and are usually drilled at intervals of 3 to 10 mm vertically and horizontally, so that the design is not noticeably impaired and the sound absorbing effect is still there, so that the rock wool sound absorbing board has excellent sound absorbing properties and design, and also, According to the manufacturing method of the present invention, the fine sound-absorbing holes can be drilled in one go using a press mold in which drilling pins of shapes corresponding to the hole diameter and depth are implanted so as to correspond to the drilling positions of the fine sound-absorbing holes, which has the effect of improving manufacturing efficiency and has great industrial applicability. [Explanation of symbols]

[0026] 1. Rock wool sound-absorbing board 2 Rock wool substrate 3 Micro sound absorbing holes 11 Press mold 11a Mold base 11b Insertion hole 12 Perforating Pins 12a Cylindrical shaft 12b pin 15 Upper die set 16 Die Plate 17 Lower die set 20 Insertion hole 21 Stripper plate 22 Guide rail

Claims

1. A step of forming rock wool, which is an artificial mineral fiber, into a plate shape to produce a rock wool substrate; applying a coating to the surface of the rock wool substrate; and a step of drilling a large number of fine sound-absorbing holes, each having a diameter of 0.3 to 2 mm and a depth of 0.5 to 5 mm, vertically and uniformly on the surface of the rock wool substrate to which the coating has been applied. A method for manufacturing rock wool sound-absorbing boards, characterized in that the drilling of the numerous fine sound-absorbing holes is carried out using a press mold in which drilling pins of shapes corresponding to the hole diameter and depth are implanted so as to correspond to the drilling positions of the fine sound-absorbing holes.

2. The method for manufacturing a rock wool sound absorbing panel according to claim 1, wherein the perforation pins of the press die are replaceable.

3. A method for manufacturing a rock wool sound-absorbing board as described in claim 1, in which the rock wool substrate is supported by guide rails extending forward and backward on both sides of the press mold set in a press machine, and the rock wool substrate is shot multiple times while being advanced along the guide rails.

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