JP2004292253A - Heat insulating material for automobile and its manufacture method - Google Patents
Heat insulating material for automobile and its manufacture method Download PDFInfo
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- JP2004292253A JP2004292253A JP2003088076A JP2003088076A JP2004292253A JP 2004292253 A JP2004292253 A JP 2004292253A JP 2003088076 A JP2003088076 A JP 2003088076A JP 2003088076 A JP2003088076 A JP 2003088076A JP 2004292253 A JP2004292253 A JP 2004292253A
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- heat insulating
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Abstract
Description
【０００１】
【発明の属する技術分野】
本発明は、自動車用の断熱材及びその製造方法に関する。
【０００２】
【従来の技術】
従来から、自動車には各所に断熱材が用いられており、例えば、エンジンの排気ガス系統に熱の遮断のために断熱材が取り付けられている。また、エンジンルームの下面にエンジン保護のために設けられているアンダーカバーに、エンジンの騒音の遮断も兼ねて熱を遮断するためのアンダーカバー用の断熱材が取り付けられている。更にまた、ボンネットの裏面や、エンジンルームと車室とを仕切るダッシュパネルにも、エンジンからの熱を遮断するためのフードサイレンサーあるいはダッシュサイレンサーと呼ばれる断熱材が取り付けられている。
【０００３】
これら自動車の各所に用いられる断熱材として、従来、グラスウールをマット状ないしフェルト状に成形したものが多用されている（例えば、特許文献１参照）。しかし、Ｅガラス繊維を用いた断熱材は、Ｅガラス繊維の耐熱性が７００℃程度までしかなく、７００℃を超える部分で使用することができない。また、近年環境問題が重視される中で、Ｅガラス繊維を用いた断熱材は、廃棄処分に際して焼却処分をしようとしてもＥガラス繊維が溶融して焼却炉の壁に付着するため、焼却処分できないという不都合が生じる。更にまた、Ｅガラス繊維を用いた断熱材は、一般に、Ｅガラス繊維の短繊維に熱硬化性樹脂バインダーを付着させて集綿し、それを加熱成形して熱硬化性樹脂バインダーを硬化させて成形しただけのものであるため、強度が十分ではなく、エンジンの振動により繊維が飛散したり、形状破壊を起こす可能性もある。
【特許文献１】
特開昭５８−１７７７８１号公報
【０００４】
【発明が解決しようとする課題】
本発明はこのような状況に鑑みてなされたものであり、７００℃を超える熱にも耐え得る優れた耐熱性を有し、かつ高強度で、酸やアルカリに対する耐性にも優れ、更には廃棄処分に当たって容易に焼却処分し得る自動車用断熱材を提供することを目的とする。
【０００５】
【課題を解決するための手段】
本発明者は、上記目的を達成すべく鋭意研究した結果、玄武岩を溶解して繊維状にしたバサルトヤーンを用いることで、７００℃を超える熱にも耐え得る優れた耐熱性を有し、強度にも優れ、焼却処分も可能な自動車用断熱材が得られることを見出し、本発明を完成するに至った。
【０００６】
即ち、本発明は、上記目的を達成するために、以下の自動車用断熱材及びその製造方法を提供する。
（１）玄武岩を溶解し繊維状としたバサルトヤーンの短繊維のフェルト状物からなることを特徴とする自動車用断熱材。
（２）表面に金属箔または不織布が添着されていることを特徴とする上記（１）記載の自動車用断熱材。
（３）バインダーを含有し、立体形状に成形されたことを特徴とする上記（１）記載の自動車用断熱材。
（４）玄武岩を溶解して長繊維状にしたバサルトヤーンを多数本収束剤で束ね、これを短繊維状に切断し、得られた短繊維を解繊してバルキー状となし、得られたバルキー状短繊維をニードル加工によりフェルト状にすることを特徴とする自動車用断熱材の製造方法。
（５）フェルト状にした後、表面に金属箔または不織布を添着することを特徴とする上記（４）記載の自動車用断熱材の製造方法。
（６）フェルト状にした後、バインダーを含浸させ、立体形状に成形することを特徴とする上記（４）記載の自動車用断熱材の製造方法。
【０００７】
【発明の実施の形態】
以下、本発明に関して詳細に説明する。
【０００８】
本発明で用いるバサルトヤーンは、玄武岩を溶解し、それを多孔のブッシングより引き出してフィラメント状の長繊維のヤーンとしたものである。また、このバサルトヤーンは、繊維のうち非晶質が６８％以下で、結晶質を３２％までを含むもので、鉄を含むことも大きな特徴である。
【０００９】
本発明の自動車用断熱材を製造するには、先ず、この長繊維状のバサルトヤーンを多数本束ね、収束剤を使用して長尺のバサルトヤーンの束とする。バサルトヤーン１本の繊維径は必要に応じて適宜設定することができるが、９〜１７μｍが好ましい。また、バサルトヤーンの束におけるバサルトヤーンの本数も必要に応じて適宜設定することができるが、５００〜４，０００本が好ましい。
【００１０】
次いで、上記のバサルトヤーンの束を短繊維状に切断し、得られたバサルト短繊維を解繊してバルキー状短繊維とする。このとき、バサルト短繊維の繊維長は必要に応じて適宜設定することができるが、５０〜２００ｍｍが好ましい。切断方法は、周知の繊維状物の切断方法によることができる。また、バサルト短繊維の解繊の方法も、周知の繊維状物の解繊方法によることができる。例えば、ノズル中にバサルト短繊維を供給するとともに、そのノズル中に圧搾空気を吹き込み、この圧搾空気でバサルト短繊維を単繊維状態に解した後にノズルから排出する方法が挙げられる。
【００１１】
そして、上記の如くして得たバルキー状短繊維を集綿し、ニードル加工によりフェルト状とすることにより、本発明の自動車用断熱材が得られる。ニードル加工は、周知の繊維状物のニードル加工方法によることができる。得られる自動車用断熱材の密度としては、７０〜２００ｇ／ｍ３が断熱性能の上で好ましく、ニードル加工条件を適宜調整する。ニードル加工により、バサルト短繊維同士が均一に強固に絡み合ったフェルト状となるため、形状安定性に優れ、繊維の飛散も抑えられる。
【００１２】
上記の如くして得られた本発明の自動車用断熱材には、更に耐熱性の向上や、バラスト短繊維の脱離を防止する等の目的で、種々の加工を施すことができる。例えば、表面に金属箔を溶着して、金属箔を備える構成とすることができる。金属箔としては、銅箔、アルミ箔、ステンレス箔等が適当である。また、金属箔は両面に添着されても、片面にのみ添着されてもよく、用途に応じて選択される。このような、表面に金属箔を添着した断熱材は、特にエンジンルーム用断熱材として好適に用いることができる。
【００１３】
また、金属箔の代わりに不織布を接着してもよい。不織布は、撥水性、耐熱性、耐油性、難燃性を有していることが好ましく、例えば名古屋油化製ＤＦＫ（ジフェノールホルムアルデヒドケトン樹脂）含浸不織布を好適に用いることができ、同様に耐熱性接着剤を用いて接着することができる。また、この表面に不織布を添着した断熱材も、特にエンジンルーム用断熱材として好適に用いることができる。
【００１４】
更に、フェルト状の断熱材にバインダーを含浸させ、金型等を用いて所望の立体形状に成形することもできる。この際、バインダーとしては、フェノール樹脂、メラミン樹脂等の熱硬化性樹脂、コロイダルシリカ、ベントナイト等の無機結着剤が好ましく用いられる。バインダーの含浸量は制限がなく、所定の形状に維持できる量であればよい。本構成によれば種々の形状となるため、排気管等の複雑な形状の部位の断熱材として好適となる。
【００１５】
本発明の自動車用断熱材に用いるバサルトフェルトの耐熱温度は約９００℃であり、グラスウール（約８００℃で溶解）よりも高温での使用に十分に耐え得るばかりでなく、燃焼により容易に分解して焼却炉の炉壁に付着することもなく、破棄処分においても有利である。また、焼却に際して、含有成分である鉄を回収できるため、鉄のリサイクルも可能になる。
【００１６】
【実施例】
以下、実施例により本発明を更に説明するが、本発明は以下の実施例に限定されるものではない。
【００１７】
玄武岩から得た長繊維状のバサルトヤーンを、収束剤としてポリビニルアルコールをバサルトヤーンに対して１．５重量％用いて、一束当たり１，０００本の束とし、これを長さ１００〜１５０ｍｍの短繊維状に切断した。次いで、得られたバサルト短繊維を解繊してバルキー状短繊維となし、これを集綿してニードル加工して厚さ８ｍｍ、密度１３０ｇ／ｍ３のフェルト状の断熱材を得た。
【００１８】
得られた断熱材は、９００℃の高温で８時間経過後の収縮率が２％と低く、高温に耐え得る耐熱性を有しており、形状安定性にも優れていた。また、断熱材を焼却したところ、バサルト繊維は粉末状になって、廃棄処分に際して容易に焼却処分できるものであった。
【００１９】
【発明の効果】
以上説明したように、本発明によれば、７００℃を超える熱にも耐え得る優れた耐熱性を有し、かつ高強度で、酸やアルカリに対する耐性にも優れ、繊維が飛散したり、形状破壊の起こる恐れがなく、更には廃棄処分に当たって、焼却処分するとバサルト繊維は粉末状になるので、容易に焼却処分でき、更に鉄のリサイクルが可能な自動車用断熱材が提供される。また、本発明の断熱材は、その表面に金属箔あるいは不織布を設けたり、バインダーを含浸させ所望の立体的形状に成形するなど、種々の加工を施して種々の態様で自動車用断熱材として用いることができる。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a heat insulating material for an automobile and a method for manufacturing the same.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, heat insulating materials are used in various places in automobiles, and for example, heat insulating materials are attached to an exhaust gas system of an engine to shut off heat. In addition, an undercover provided on the lower surface of the engine room for protecting the engine is provided with a heat insulating material for the undercover for blocking heat while also blocking engine noise. Further, a heat insulating material called a hood silencer or a dash silencer for shutting off heat from the engine is attached to a back surface of the hood and a dash panel separating an engine room and a vehicle compartment.
[0003]
Conventionally, as a heat insulating material used in various parts of these automobiles, a glass wool molded into a mat shape or a felt shape is widely used (for example, see Patent Document 1). However, the heat insulating material using E glass fiber has heat resistance of E glass fiber only up to about 700 ° C., and cannot be used in a portion exceeding 700 ° C. In recent years, in consideration of environmental issues, heat insulating materials using E glass fiber cannot be incinerated because the E glass fiber is melted and adheres to the wall of the incinerator even if it is incinerated at the time of disposal. Inconvenience occurs. Furthermore, the heat insulating material using E glass fiber is generally obtained by adhering a thermosetting resin binder to the short fiber of E glass fiber, collecting the cotton, and heat molding the same to cure the thermosetting resin binder. Since it is merely molded, the strength is not sufficient, and the fibers may be scattered or the shape may be broken by the vibration of the engine.
[Patent Document 1]
JP-A-58-177781
[Problems to be solved by the invention]
The present invention has been made in view of such circumstances, and has excellent heat resistance that can withstand heat exceeding 700 ° C., and has high strength, excellent resistance to acids and alkalis, and furthermore disposal. An object of the present invention is to provide a heat insulating material for automobiles that can be easily incinerated for disposal.
[0005]
[Means for Solving the Problems]
The inventor of the present invention has conducted intensive studies to achieve the above object, and as a result, by using basalt yarn obtained by dissolving basalt into a fibrous form, it has excellent heat resistance that can withstand heat exceeding 700 ° C. The present inventors have found that a heat insulating material for automobiles that is excellent in heat resistance and can be incinerated can be obtained, and the present invention has been completed.
[0006]
That is, the present invention provides the following automotive heat insulating material and a method for manufacturing the same in order to achieve the above object.
(1) A heat insulating material for automobiles comprising a felt-like basalt yarn short fiber made by dissolving basalt.
(2) The heat insulating material for an automobile according to the above (1), wherein a metal foil or a nonwoven fabric is adhered to the surface.
(3) The heat insulating material for automobiles according to the above (1), which contains a binder and is formed into a three-dimensional shape.
(4) A large number of basalt yarns obtained by dissolving basalt into long fibers are bundled with this sizing agent, cut into short fibers, and the obtained short fibers are defibrated into a bulky shape to obtain a staple fiber. A method for producing a heat insulating material for automobiles, wherein the bulky short fibers are made into a felt shape by needle processing.
(5) The method for producing a heat insulating material for an automobile according to the above (4), wherein a metal foil or a nonwoven fabric is attached to the surface after the felt is formed.
(6) The method for producing a heat insulating material for an automobile according to the above (4), wherein the heat insulating material is formed into a three-dimensional shape by impregnating with a binder after forming into a felt shape.
[0007]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described in detail.
[0008]
The basalt yarn used in the present invention is obtained by dissolving basalt and extracting it from a porous bushing to obtain a filament-shaped long fiber yarn. The basalt yarn has an amorphous content of 68% or less of the fiber and a crystalline content of up to 32%, and is characterized by containing iron.
[0009]
In order to manufacture the heat insulating material for automobiles of the present invention, first, a large number of the long fiber basalt yarns are bundled, and a long basalt yarn bundle is formed using a sizing agent. The fiber diameter of one basalt yarn can be appropriately set as needed, but is preferably 9 to 17 μm. The number of basalt yarns in the basalt yarn bundle can also be appropriately set as needed, but is preferably 500 to 4,000.
[0010]
Next, the basalt yarn bundle is cut into short fibers, and the obtained basalt short fibers are defibrated into bulky short fibers. At this time, the fiber length of the basalt short fibers can be appropriately set as needed, but is preferably 50 to 200 mm. The cutting method can be based on a known fibrous material cutting method. In addition, the defibrating method of the basalt staple fiber may be a known fibrous material defibrating method. For example, there is a method in which basalt short fibers are supplied into a nozzle, compressed air is blown into the nozzle, the basalt short fibers are broken into a single fiber state by the compressed air, and then discharged from the nozzle.
[0011]
Then, the bulky short fibers obtained as described above are collected and made into a felt shape by needle processing, whereby the heat insulating material for automobiles of the present invention is obtained. Needle processing can be performed by a known fibrous material needle processing method. The density of the obtained heat insulating material for automobiles is preferably 70 to 200 g / m 3 from the viewpoint of heat insulating performance, and the conditions for needle processing are appropriately adjusted. By the needle processing, since the basalt short fibers are uniformly and strongly entangled into a felt shape, the shape is excellent and the scattering of the fibers is suppressed.
[0012]
The heat insulating material for automobiles of the present invention obtained as described above can be subjected to various processings for the purpose of further improving heat resistance and preventing detachment of short ballast fibers. For example, a configuration in which a metal foil is provided by welding a metal foil to the surface can be employed. As the metal foil, a copper foil, an aluminum foil, a stainless steel foil or the like is suitable. Further, the metal foil may be attached to both sides or only one side, and is selected according to the application. Such a heat insulating material having a metal foil attached to the surface can be suitably used particularly as an engine room heat insulating material.
[0013]
Further, a nonwoven fabric may be bonded instead of the metal foil. The nonwoven fabric preferably has water repellency, heat resistance, oil resistance, and flame retardancy. For example, DFK (diphenol formaldehyde ketone resin) impregnated nonwoven fabric manufactured by Nagoya Yuka Co., Ltd. can be suitably used. It can be adhered using a conductive adhesive. A heat insulating material having a nonwoven fabric attached to the surface can also be suitably used as a heat insulating material particularly for an engine room.
[0014]
Furthermore, a felt-like heat insulating material can be impregnated with a binder and formed into a desired three-dimensional shape using a mold or the like. At this time, as the binder, a thermosetting resin such as a phenol resin and a melamine resin, and an inorganic binder such as colloidal silica and bentonite are preferably used. The amount of the binder impregnated is not limited, and may be any amount that can maintain a predetermined shape. According to this configuration, various shapes are obtained, so that it is suitable as a heat insulating material for a portion having a complicated shape such as an exhaust pipe.
[0015]
The heat-resistant temperature of the basalt felt used in the heat insulating material for automobiles of the present invention is about 900 ° C., which can not only sufficiently withstand use at a temperature higher than glass wool (dissolved at about 800 ° C.), but also easily decompose by burning. It does not adhere to the walls of incinerators and is advantageous in disposal. In addition, at the time of incineration, iron as a contained component can be recovered, so that iron can be recycled.
[0016]
【Example】
Hereinafter, the present invention will be further described with reference to examples, but the present invention is not limited to the following examples.
[0017]
A long fiber basalt yarn obtained from basalt was used as a sizing agent with polyvinyl alcohol at 1.5% by weight based on the basalt yarn to make 1,000 bundles per bundle, which were 100 to 150 mm in length. It was cut into short fibers. Next, the obtained basalt staple fibers were defibrated into bulky staple fibers, which were collected and needled to obtain a felt-like heat insulating material having a thickness of 8 mm and a density of 130 g / m 3 .
[0018]
The obtained heat insulating material had a low shrinkage of 2% after 8 hours at a high temperature of 900 ° C., had heat resistance enough to withstand the high temperature, and was excellent in shape stability. Further, when the heat insulating material was incinerated, the basalt fibers became powdery and could be easily incinerated when disposed.
[0019]
【The invention's effect】
As described above, according to the present invention, it has excellent heat resistance that can withstand heat exceeding 700 ° C., and has high strength, excellent resistance to acids and alkalis, and fibers can be scattered or shaped. Since there is no risk of destruction, and furthermore, the basalt fiber becomes powdery when incinerated for disposal, an automotive insulation material that can be easily incinerated and that can be recycled iron is provided. Further, the heat insulating material of the present invention is used as a heat insulating material for automobiles in various modes by performing various processes such as providing a metal foil or a nonwoven fabric on its surface, or impregnating a binder to form a desired three-dimensional shape. be able to.
Claims (6)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2003088076A JP2004292253A (en) | 2003-03-27 | 2003-03-27 | Heat insulating material for automobile and its manufacture method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2003088076A JP2004292253A (en) | 2003-03-27 | 2003-03-27 | Heat insulating material for automobile and its manufacture method |
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| Publication Number | Publication Date |
|---|---|
| JP2004292253A true JP2004292253A (en) | 2004-10-21 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2003088076A Pending JP2004292253A (en) | 2003-03-27 | 2003-03-27 | Heat insulating material for automobile and its manufacture method |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100698403B1 (en) * | 2005-02-04 | 2007-03-26 | 삼우기업 주식회사 | Mehtod for manufacturing nonwoven fabric using mineral fiber and method manufacturing interior materials of automobile using that |
| JP2007146691A (en) * | 2005-11-24 | 2007-06-14 | Toyota Motor Corp | Sub muffler |
| WO2014073860A1 (en) * | 2012-11-06 | 2014-05-15 | 현대자동차 주식회사 | Method for manufacturing highly heat-resistant sound absorbing and screening material |
-
2003
- 2003-03-27 JP JP2003088076A patent/JP2004292253A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100698403B1 (en) * | 2005-02-04 | 2007-03-26 | 삼우기업 주식회사 | Mehtod for manufacturing nonwoven fabric using mineral fiber and method manufacturing interior materials of automobile using that |
| JP2007146691A (en) * | 2005-11-24 | 2007-06-14 | Toyota Motor Corp | Sub muffler |
| WO2014073860A1 (en) * | 2012-11-06 | 2014-05-15 | 현대자동차 주식회사 | Method for manufacturing highly heat-resistant sound absorbing and screening material |
| US9956927B2 (en) | 2012-11-06 | 2018-05-01 | Hyundai Motor Company | Manufacturing method of highly heat-resistant sound absorbing and insulating materials |
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