JP6557464B2 - Insulating fiber-absorbing sound absorbing material having flexibility and method for producing the same - Google Patents
Insulating fiber-absorbing sound absorbing material having flexibility and method for producing the same Download PDFInfo
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Description
本発明は、製造時のエネルギー消費が少なく、住宅や建物への施工に適した、優れた剛性と柔軟な風合いを有した無機繊維断熱吸音材とその製造方法に関する。 The present invention relates to an inorganic fiber heat insulating sound absorbing material having excellent rigidity and flexible texture, which consumes less energy during production and is suitable for construction in a house or building, and a method for producing the same.
従来から、グラスウール等の無機繊維からなる断熱吸音材において、繊維間を接着するバインダーとして、水溶性フェノール・ホルムアルデヒド樹脂を主成分としたフェノール系バインダーが広く使用されている（例えば、特許文献１）。フェノール系バインダーは加熱により硬化し、その硬化物は剛性と耐水性に優れていることから、それを用いた断熱吸音材は、圧縮梱包品の開梱後の復元厚さ等に優れている。 Conventionally, in heat-absorbing sound-absorbing materials made of inorganic fibers such as glass wool, a phenolic binder mainly composed of a water-soluble phenol / formaldehyde resin has been widely used as a binder for bonding fibers (for example, Patent Document 1). . Since the phenol-based binder is cured by heating and the cured product is excellent in rigidity and water resistance, the heat insulating sound-absorbing material using the phenol-based binder is excellent in the restored thickness after unpacking of the compressed package.
無機繊維断熱吸音材は、通常、無機繊維の紡糸から樹脂を硬化させ成形するまでを連続で生産している。その為、フェノール系バインダーを短時間で硬化させる必要がある。その為には、高い硬化温度が必要となる。 The inorganic fiber heat-absorbing sound-absorbing material is usually produced continuously from spinning of inorganic fibers to curing and molding of the resin. Therefore, it is necessary to cure the phenolic binder in a short time. For this purpose, a high curing temperature is required.
フェノール系バインダーの硬化物は、硬い風合いを特徴としている。しかし、その硬化物は、柔軟性に劣り、人間が把持した場合、皮膚に刺さるような悪い触感を与える。その為、フェノール系バインダーには柔軟性の付与を目的として、重質オイル等の水分散体等の柔軟剤を混合する方法が広く使用される。 A cured product of the phenolic binder is characterized by a hard texture. However, the cured product is inferior in flexibility, and gives a bad tactile sensation that pierces the skin when held by a human. Therefore, a method of mixing a softener such as an aqueous dispersion such as heavy oil is widely used for the purpose of imparting flexibility to the phenolic binder.
フェノール系樹脂は、短時間で硬化する為には、２００℃から３５０℃と高い温度が必要となり、その温度に加熱する為に多大な熱エネルギーを消費する。 A phenolic resin requires a high temperature of 200 ° C. to 350 ° C. in order to be cured in a short time, and consumes a large amount of heat energy to heat to that temperature.
柔軟性の付与を目的として混合される重質オイル等の水分散体の耐熱性は、２５０℃程度と低く、フェノール系バインダーの硬化する温度と近い。その為、フェノール系バインダーの硬化と、重質オイルの分解が並行して起こり、得られた無機繊維断熱吸音材中の重質オイルの含有量が低下する恐れがある。重質オイルが低下した場合、無機繊維断熱吸音材の柔軟性が劣り、人間が把持した場合に皮膚に刺さる様な悪い触感を感じる。そして、柔軟性を追求した柔軟剤の過度の添加は無機繊維断熱吸音材の剛性を弱くし、施工性が悪化する問題があった。 The heat resistance of an aqueous dispersion such as heavy oil mixed for the purpose of imparting flexibility is as low as about 250 ° C., which is close to the curing temperature of the phenolic binder. Therefore, the curing of the phenolic binder and the decomposition of the heavy oil occur in parallel, and the content of the heavy oil in the obtained inorganic fiber heat-absorbing sound-absorbing material may be lowered. When the heavy oil is lowered, the flexibility of the inorganic fiber heat-absorbing sound-absorbing material is inferior, and when it is grasped by humans, it feels bad touch such as piercing the skin. And the excessive addition of the softener which pursued the softness | flexibility weakened the rigidity of the inorganic fiber heat insulation sound-absorbing material, and there existed a problem which workability deteriorated.
したがって、本発明の目的は、重質オイル等の水分散体の柔軟性を損なう事のない低い温度での硬化が可能であり、製造時のエネルギー消費が少なく、優れた剛性と柔軟な風合いを有する住宅や建物への施工に適した無機繊維断熱吸音材を提供することである。
Therefore, the object of the present invention is that it can be cured at a low temperature without impairing the flexibility of an aqueous dispersion such as heavy oil, has low energy consumption during production, and has excellent rigidity and flexible texture. An object of the present invention is to provide an inorganic fiber heat-absorbing and sound-absorbing material suitable for construction in houses and buildings.
本発明者らは、上記課題を達成するために、鋭意に検討した結果、本発明に達した。
１）熱可塑性樹脂を主成分とした水溶性ポリマーと、架橋剤と、柔軟剤とを含有し、低温加熱により成形が可能な水溶性バインダーであること。
２）前記熱可塑性樹脂が、ポリビニルアルコール系樹脂であること。
３）前記架橋剤は、（ａ）ポリカルボン酸の化合物、重合物若しくは共重合物、（ｂ）ほう素化合物、又は、（ｃ）それらの混合物より選択される１種類であること。
４）前記柔軟剤は、（Ａ）重質オイル、（Ｂ）シリコーンオイル、又は（Ｃ）その混合物の水分散体であること。
５）１〜４の水溶性バインダーを無機繊維に付与し、１００℃から２００℃の低温加熱処理によって成形すること。
The inventors of the present invention have reached the present invention as a result of intensive studies to achieve the above-mentioned problems.
1) A water-soluble binder which contains a water-soluble polymer mainly composed of a thermoplastic resin, a crosslinking agent, and a softening agent and can be molded by low-temperature heating.
2) The thermoplastic resin is a polyvinyl alcohol resin.
3) The crosslinking agent is one kind selected from (a) a compound of a polycarboxylic acid, a polymer or copolymer, (b) a boron compound, or (c) a mixture thereof.
4) The softener is an aqueous dispersion of (A) heavy oil, (B) silicone oil, or (C) a mixture thereof.
5) Applying 1 to 4 water-soluble binders to the inorganic fiber, and molding by low-temperature heat treatment from 100 ° C to 200 ° C.
本発明の水溶性バインダーは、ポリビニルアルコール系樹脂であり、その硬化温度は、フェノール系樹脂に比べ、格段に低い。その為、無機繊維断熱吸音材の成形温度を格段に下げる事が可能となり、加熱に必要な熱エネルギーの消費を低減できる。 The water-soluble binder of the present invention is a polyvinyl alcohol resin, and its curing temperature is much lower than that of a phenol resin. Therefore, the molding temperature of the inorganic fiber heat-absorbing sound absorbing material can be remarkably lowered, and consumption of heat energy necessary for heating can be reduced.
本発明に用いる柔軟剤は、２５０℃の高い温度の場合、十分に無機繊維断熱吸音材を柔軟にすることができない。何故ならば、重質オイルの耐熱性が２５０℃程度だからである。従って、硬化するための加熱温度は、２００℃を上限とする。
本発明の水溶性バインダーは、低い温度での硬化が可能になる事で、混合した柔軟剤の性能を十分に発揮する事ができる。その為、住宅や建物への施工に適した剛性と柔軟性を有した無機繊維断熱吸音材を提供することができる。
The softening agent used in the present invention cannot sufficiently soften the inorganic fiber heat-absorbing sound-absorbing material when the temperature is as high as 250 ° C. This is because the heat resistance of heavy oil is about 250 ° C. Therefore, the upper limit of the heating temperature for curing is 200 ° C.
Since the water-soluble binder of the present invention can be cured at a low temperature, the performance of the mixed softener can be sufficiently exhibited. Therefore, it is possible to provide an inorganic fiber heat insulating sound absorbing material having rigidity and flexibility suitable for construction in a house or a building.
本発明の水溶性バインダーは、熱可塑性樹脂を主成分とした水溶性ポリマーと、架橋剤と、柔軟剤とを含有し、１００℃から２００℃の加熱により硬化が可能な水溶性バインダーであること。 The water-soluble binder of the present invention is a water-soluble binder that contains a water-soluble polymer mainly composed of a thermoplastic resin, a crosslinking agent, and a softening agent and can be cured by heating at 100 ° C. to 200 ° C. .
本発明の無機繊維用水溶性バインダーに用いる水溶性ポリマーは、ポリビニルアルコール系樹脂が望ましい。ポリビニルアルコール系樹脂は、フェノール系樹脂と比較して、硬化温度が１００℃から２００℃であり、低い温度での硬化が可能となる。 The water-soluble polymer used for the water-soluble binder for inorganic fibers of the present invention is preferably a polyvinyl alcohol resin. The polyvinyl alcohol resin has a curing temperature of 100 ° C. to 200 ° C. as compared with the phenol resin, and can be cured at a low temperature.
ポリビニルアルコール系樹脂としては、特に限定はしないが、ポリビニルアルコール系樹脂の重合度が水溶液の粘度に直接影響する為、塗布装置のスプレー適性に合わせて選択する必要がある。例えば、日本酢ビ・ポバール社製の「ＪＬ−０５Ｅ」が挙げられるが、本発明は、これに限定されない。 Although it does not specifically limit as a polyvinyl alcohol-type resin, Since the polymerization degree of a polyvinyl alcohol-type resin has a direct influence on the viscosity of aqueous solution, it is necessary to select according to the sprayability of a coating device. For example, “JL-05E” manufactured by Nippon Vinegar Poval Co., Ltd. may be mentioned, but the present invention is not limited thereto.
本発明の無機繊維用水溶性バインダーに用いる架橋剤（ａ）（ｂ）（ｃ）は、上記ポリビニルアルコール系樹脂を１００質量部に対し、固形分換算で４．０質量部以上を含有することが好ましい。４．０質量部未満だと、ポリビニルアルコール系樹脂との架橋反応が十分に行われず、無機繊維断熱吸音材の剛性の低下に繋がる。
尚、架橋剤の上限は、特に限定するものではないが、経済性の観点からすると、ポリビニルアルコール系樹脂１００.０質量部に対して、１００.０質量部以下が好ましい。
The crosslinking agents (a), (b), and (c) used in the water-soluble binder for inorganic fibers of the present invention may contain 4.0 parts by mass or more in terms of solid content with respect to 100 parts by mass of the polyvinyl alcohol resin. preferable. When the amount is less than 4.0 parts by mass, the crosslinking reaction with the polyvinyl alcohol resin is not sufficiently performed, leading to a decrease in rigidity of the inorganic fiber heat-absorbing sound-absorbing material.
In addition, although the upper limit of a crosslinking agent is not specifically limited, From an economical viewpoint, 100.0 mass parts or less are preferable with respect to 100.0 mass parts of polyvinyl alcohol-type resin.
前記架橋剤（ａ）としては、脂肪族カルボン酸単量体より選択される１種類以上の単量体の化合物、重合物または共重合物である。上記脂肪族カルボン酸単量体としては、アクリル酸系、メタクリル酸系、クロトン酸系等の脂肪族モノカルボン酸類の重合物、又、共重合物、マレイン酸系、フマル酸系、イタコン酸系等の脂肪族ジカルボン酸類の化合物、重合物、又、共重合物が好ましい。ポリビニルアルコール系樹脂との反応性を考慮すると、単量体中に２個のカルボン酸を持つマレイン酸系共重合物が更に好ましい。例えば、五協産業社製の「ガントレンツＡＮ −１１９」が挙げられるが、本発明は、これに限定されない。 The crosslinking agent (a) is a compound, polymer or copolymer of one or more monomers selected from aliphatic carboxylic acid monomers. Examples of the aliphatic carboxylic acid monomer include polymers of aliphatic monocarboxylic acids such as acrylic acid, methacrylic acid, and crotonic acid, and copolymers, maleic acid, fumaric acid, and itaconic acid. A compound, polymer, or copolymer of an aliphatic dicarboxylic acid such as Considering the reactivity with the polyvinyl alcohol resin, a maleic acid copolymer having two carboxylic acids in the monomer is more preferable. An example is “Gantrenz AN-119” manufactured by Gokyo Sangyo Co., Ltd., but the present invention is not limited to this.
前記架橋剤（ｂ）としては、ホウ素化合物であって、ホウ砂、ホウ酸、ホウ酸錯体等が挙げられる。ホウ素系化合物は、混合撹拌時に架橋反応を行う為、水溶液の過度な粘度増加が見られる恐れがあり、低濃度の水溶液として添加する事が望ましい。好ましくは、市販されているホウ砂を４％水溶液に調整したものが挙げられるが、本発明は、これに限定されない。 Examples of the cross-linking agent (b) include boron compounds such as borax, boric acid, and boric acid complexes. Since the boron-based compound undergoes a crosslinking reaction during mixing and stirring, an excessive increase in viscosity of the aqueous solution may be observed, and it is desirable to add it as a low-concentration aqueous solution. Preferably, commercially available borax is prepared as a 4% aqueous solution, but the present invention is not limited to this.
前記架橋剤（ｃ）としては、前記架橋剤（ａ）と（ｂ）の混合物である。耐水性の効果や水溶液の粘度状態に応じて、架橋剤（ａ）（ｂ）を併用して使用できる。従来、フィルム成形の分野では、（ｂ）ホウ素化合物をポリビニルアルコール系樹脂と架橋させ、増粘させる目的として、（ａ）脂肪族カルボン酸系化合物をポリビニルアルコール系樹脂と架橋させ、耐水性を付与する目的として、併用して使用する事が多く、周知の技術として挙げられる。 The crosslinking agent (c) is a mixture of the crosslinking agents (a) and (b). The crosslinking agents (a) and (b) can be used in combination depending on the water resistance effect and the viscosity state of the aqueous solution. Conventionally, in the field of film forming, (b) for the purpose of crosslinking and thickening a boron compound with a polyvinyl alcohol resin, (a) crosslinking an aliphatic carboxylic acid compound with a polyvinyl alcohol resin to impart water resistance For this purpose, it is often used in combination and is known as a well-known technique.
本発明においては、下記に記述する柔軟剤（Ａ）、（Ｂ）及び（Ｃ）が添加される。柔軟剤は重質オイルやシリコーンオイルに界面活性剤を混合し、水に分散させたものである。これら柔軟剤は、樹脂と混ざり合い、硬化物に取り込まれる事で、その硬化物に柔軟性を付与する事ができる。柔軟性が付与できた硬化物は、無機繊維断熱吸音材に柔らかい触感を与える。特に、ポリビニルアルコール系樹脂は、柔軟剤との相溶性に優れ、その効果を発揮しやすい。
本発明の無機繊維用水溶性バインダーに用いる柔軟剤（Ａ）（Ｂ）（Ｃ）としては、前記ポリビニルアルコール系樹脂と前記架橋剤との合計１００質量部に対し、５．０から３０.０質量部含有することが好ましい。５．０質量部より少ないと、柔軟剤としての効果を発揮することができない。５．０質量部以上だと、柔軟剤としてより有効に効果を発揮することができる。３０．０質量部を超えると、無機繊維断熱吸音材の剛性の低下に繋がり、施工性が悪化する。
In the present invention, softening agents (A), (B) and (C) described below are added. The softening agent is obtained by mixing a heavy oil or silicone oil with a surfactant and dispersing it in water. These softening agents can be mixed with a resin and taken into a cured product to impart flexibility to the cured product. The hardened | cured material which was able to provide the softness | flexibility gives a soft touch to an inorganic fiber heat-insulating sound-absorbing material. In particular, the polyvinyl alcohol-based resin is excellent in compatibility with the softening agent and easily exhibits its effect.
As a softening agent (A) (B) (C) used for the water-soluble binder for inorganic fibers of the present invention, 5.0 to 30.0 mass with respect to a total of 100 mass parts of the polyvinyl alcohol resin and the crosslinking agent. It is preferable to contain a part. When the amount is less than 5.0 parts by mass, the effect as a softening agent cannot be exhibited. When it is 5.0 parts by mass or more, the effect can be more effectively exhibited as a softening agent. When it exceeds 30.0 mass parts, it will lead to the fall of the rigidity of an inorganic fiber heat insulation sound-absorbing material, and workability will deteriorate.
上記柔軟剤（Ａ）としては、重質オイルの水分散体であり、防塵性の付与に高い効果を示す。重質オイルの粘度グレードでＶＧ３２０、ＶＧ４６０、ＶＧ６８０をベース油としたエマルションのものが好ましい。ＶＧ３２０より小さいグレードでは、加熱処理時の揮発が大きくなり、柔軟剤としての効果が弱くなる恐れがある。ＶＧ６８０より大きいグレードでは、無機繊維用バインダーの粘度増加に影響し、無機繊維へのスプレー性が悪化する恐れがある。好ましくは、出光興産社製の「ダフニープロソルブルＰＦ」が挙げられるが、本発明は、これに限定されない。 The softener (A) is an aqueous dispersion of heavy oil, and exhibits a high effect on imparting dust resistance. A heavy oil having a viscosity grade of VG320, VG460, or VG680 as a base oil is preferred. In grades smaller than VG320, volatilization during heat treatment increases, and the effect as a softener may be weakened. In the grade larger than VG680, the viscosity increase of the binder for inorganic fibers is affected, and the sprayability to the inorganic fibers may be deteriorated. Preferably, “Dafney Prosolvable PF” manufactured by Idemitsu Kosan Co., Ltd. can be mentioned, but the present invention is not limited to this.
上記柔軟剤（Ｂ）としては、シリコーンオイルの水分散体であり、柔軟性の付与に高い効果を示す。シリコーンオイルとしては、ジメチルタイプ、アミノ変性、エポキシ変性、水素変性等の有機官能性タイプのポリシロキサン系オイルのエマルションが好ましい。特にジメチルタイプは、ポリビニルアルコール系樹脂に対し、強い滑りがあり、優れた柔軟性を付与できる為、更に好ましい。例えば、信越化学社製の「Ｐｏｌｏｎ ＭＲ」が挙げられるが、本発明は、これに限定されない。 The softener (B) is an aqueous dispersion of silicone oil, and exhibits a high effect on imparting flexibility. The silicone oil is preferably an emulsion of a polysiloxane oil of an organic functional type such as dimethyl type, amino-modified, epoxy-modified or hydrogen-modified. In particular, the dimethyl type is more preferable because it has a strong slip with respect to the polyvinyl alcohol resin and can impart excellent flexibility. For example, “Polon MR” manufactured by Shin-Etsu Chemical Co., Ltd. can be mentioned, but the present invention is not limited to this.
前記柔軟剤（Ｃ）としては、前記柔軟剤（Ａ）と（Ｂ）の混合物である。防塵性と柔軟性のバランスを考慮し、必要に応じて、柔軟剤（Ａ）（Ｂ）を併用して使用できる。 The softener (C) is a mixture of the softeners (A) and (B). Considering the balance between dustproofness and flexibility, the softeners (A) and (B) can be used in combination as required.
本発明の無機繊維用水溶性バインダーは、必要に応じて、シランカップリング剤、撥水剤、着色剤、ｐＨ調整剤等の添加剤を更に添加しても良い。 The water-soluble binder for inorganic fibers of the present invention may further contain additives such as a silane coupling agent, a water repellent, a colorant, and a pH adjuster as necessary.
本発明の無機繊維用水溶性バインダーは、上記ポリビニルアルコール系樹脂と、架橋剤と、柔軟剤とを、攪拌機の付いたタンクを用いて混合し、調整することができる。 The water-soluble binder for inorganic fibers of the present invention can be prepared by mixing the polyvinyl alcohol resin, the crosslinking agent, and the softening agent using a tank equipped with a stirrer.
本発明の無機繊維用水溶性バインダーの塗布液の固形分濃度は、２から２０質量％が好ましく、２から１０質量％が更に好ましい。２０質量％より大きいと、水溶液の粘度が増加し、塗布液量が減少する事で、無機繊維に対する付着効率が低下する。２質量％未満では、水分量が多くなり、加熱処理に時間を要し、生産性が低下すると共にエネルギー消費量が大きくなってしまう。 The solid concentration of the coating solution of the water-soluble binder for inorganic fibers of the present invention is preferably 2 to 20% by mass, more preferably 2 to 10% by mass. When it is larger than 20% by mass, the viscosity of the aqueous solution increases and the amount of the coating solution decreases, so that the adhesion efficiency to the inorganic fibers decreases. If it is less than 2% by mass, the amount of water increases, and it takes time for the heat treatment, resulting in a decrease in productivity and an increase in energy consumption.
本発明の無機繊維断熱吸音材は、上記無機繊維用水溶性バインダーを無機繊維に付与し、加熱処理により硬化させて成形して得られたものである。 The inorganic fiber heat insulating sound-absorbing material of the present invention is obtained by applying the water-soluble binder for inorganic fibers to inorganic fibers and curing it by heat treatment.
バインダーの加熱硬化温度は、１００〜２００℃が好ましい。１００℃未満だと、十分に硬化しない。２００℃を超えると、硬化する為に多大なエネルギーを消費することとなるからであり、また、重質オイルの耐熱性（２５０℃）を考慮したものである。より好ましくは、１１０〜２００℃である。また、加熱硬化時間は、無機繊維断熱吸音材の密度、厚さにより選定され、６０秒〜６００秒の間で適宜調整する。より好ましくは、１５０〜５００秒である。その為、硬化時間に合わせて、硬化温度を１００〜２００℃の間で適宜調整する事が好ましい。
バインダー液の硬化時間には、測定溶液の水分蒸発も含まれており、水分蒸発時間を除くと、樹脂成分は６０秒程度で硬化する。実際の製造工程では、気温が４０〜５０℃と高温になり、スプレー時より水分の蒸発が開始する為、塗布液の濃度調整により、理論上は６０秒程度での硬化は可能である。但し、実生産では、１５０秒以上がより好ましい条件と判断した。
The heat curing temperature of the binder is preferably 100 to 200 ° C. If it is less than 100 ° C., it will not be cured sufficiently. This is because if it exceeds 200 ° C., a large amount of energy is consumed for curing, and the heat resistance (250 ° C.) of heavy oil is taken into consideration. More preferably, it is 110-200 degreeC. The heat curing time is selected depending on the density and thickness of the inorganic fiber heat-absorbing sound-absorbing material, and is appropriately adjusted between 60 seconds and 600 seconds. More preferably, it is 150 to 500 seconds. Therefore, it is preferable to appropriately adjust the curing temperature between 100 and 200 ° C. according to the curing time.
The curing time of the binder liquid includes water evaporation of the measurement solution, and the resin component is cured in about 60 seconds, excluding the water evaporation time. In the actual manufacturing process, the temperature becomes as high as 40 to 50 ° C., and the evaporation of water starts from the time of spraying. Therefore, theoretically, curing can be performed in about 60 seconds by adjusting the concentration of the coating liquid. However, in actual production, 150 seconds or more was judged as a more preferable condition.
本発明の無機繊維断熱吸音材は、例えば以下のようにして製造することができる。 The inorganic fiber heat insulating sound-absorbing material of the present invention can be produced, for example, as follows.
本発明の無機繊維断熱吸音材に用いる無機繊維としては、特に限定しないが、通常の断熱吸音材に使用されているグラスウール、ロックウール等を用いることができる。無機繊維の繊維化方法は、火焔法、吹き飛ばし法、遠心法（ロータリー法とも言う）等の各種方法を用いることができる。特に無機繊維がグラスウールの場合は、遠心法を用いることが好ましい。なお、目的とする無機繊維断熱吸音材の密度は、通常の断熱材や吸音材に使用されている密度でよく、好ましくは５〜３００ｋｇ／ｍ３の範囲である。 Although it does not specifically limit as an inorganic fiber used for the inorganic fiber heat insulation sound-absorbing material of this invention, The glass wool, the rock wool, etc. which are used for the normal heat insulation sound-absorption material can be used. Various methods such as a flame method, a blow-off method, and a centrifugal method (also referred to as a rotary method) can be used as a method for forming inorganic fibers. In particular, when the inorganic fiber is glass wool, it is preferable to use a centrifugal method. In addition, the density of the target inorganic fiber heat-insulating material may be a density used in ordinary heat-insulating materials and sound-absorbing materials, and is preferably in the range of 5 to 300 kg / m 3 .
無機繊維にバインダーを付与するには、スプレー装置等を用いて塗布、噴霧する。バインダーの付与量の調整は、従来のバインダーと同様の方法で調整することができる。そして、バインダーの付与量は、無機繊維断熱吸音材の密度や用途によって異なるが、バインダーを付与した無機繊維断熱吸音材の質量を基準として、固形分換算で０．５〜１５質量%の範囲が好ましく、０．５〜９質量％の範囲がより好ましい。 In order to impart the binder to the inorganic fibers, it is applied and sprayed using a spray device or the like. The amount of the binder applied can be adjusted by the same method as the conventional binder. And the amount of the binder applied varies depending on the density and use of the inorganic fiber heat-absorbing sound absorbing material, but on the basis of the mass of the inorganic fiber heat insulating sound-absorbing material to which the binder is added, the range of 0.5 to 15% by mass in terms of solid content is used. Preferably, the range of 0.5-9 mass% is more preferable.
無機繊維にバインダーを付与するタイミングとしては、繊維化後であればいつでも良いが、バインダーを効率的に付与させるためには、繊維化直後に付与することが好ましい。 The timing of applying the binder to the inorganic fiber may be any time after fiberization, but in order to efficiently apply the binder, it is preferable to apply it immediately after fiberization.
上記工程によってバインダーが付与された無機繊維は、繊維堆積装置内の有孔コンベア上に堆積され、嵩高い無機繊維中間体となる。繊維堆積装置は、有孔コンベアの裏面より吸引する事で無機繊維を効率的に堆積させることができる。 The inorganic fiber to which the binder has been applied by the above process is deposited on a perforated conveyor in the fiber deposition apparatus, and becomes a bulky inorganic fiber intermediate. The fiber deposition apparatus can efficiently deposit inorganic fibers by suction from the back surface of the perforated conveyor.
その後、前記無機繊維断熱吸音材中間体を、乾燥設備にて所望とする厚さになるように設定した上下一対の有孔コンベア等で連続的に狭圧し、熱風によりバインダーを硬化させて、無機繊維断熱吸音材をマット状に成形した後、所望とする幅、長さに切断する。 Thereafter, the inorganic fiber heat-insulating sound absorbing material intermediate is continuously narrowed with a pair of upper and lower perforated conveyors set to have a desired thickness in a drying facility, and the binder is cured with hot air, and inorganic After forming the fiber heat-absorbing sound-absorbing material into a mat shape, it is cut into a desired width and length.
一般に、乾燥炉は数個に区分され、各区分にて個別で温度設定が出来る構造となっている。主に水分の蒸発を行う前半部では、２００℃以上の高温での処理が可能であるが、樹脂を硬化させる後半部では、柔軟剤の揮発を抑制する為にも１００〜２００℃、好ましくは１１０〜２００℃で調整する。また、加熱時間は、６０〜６００秒、好ましくは１５０〜５００秒である。 Generally, the drying furnace is divided into several parts, and the temperature can be set individually for each section. In the first half where the water is mainly evaporated, treatment at a high temperature of 200 ° C. or higher is possible, but in the second half where the resin is cured, 100 to 200 ° C., preferably in order to suppress volatilization of the softener. Adjust at 110-200 ° C. The heating time is 60 to 600 seconds, preferably 150 to 500 seconds.
本発明の無機繊維断熱吸音材は、そのままの形態で用いてもよく、また、表皮材で被覆して用いてもよい。表皮材としては、この分野で公知の紙、合成樹脂フィルム、金属箔フィルム、不織布、織布あるいはこれらを組み合わせたものを用いることができる。 The inorganic fiber heat-absorbing sound-absorbing material of the present invention may be used as it is, or may be used after being covered with a skin material. As the skin material, paper, synthetic resin film, metal foil film, non-woven fabric, woven fabric, or a combination thereof known in this field can be used.
このようにして得られた本発明の無機繊維断熱吸音材は、従来のフェノール系バインダーと比較して、製造時のエネルギー損失が少なく、優れた剛性と柔軟な風合いを有し、住宅や建物への施工に適した無機繊維断熱吸音材を提供することができる。
The inorganic fiber heat insulating sound absorbing material of the present invention thus obtained has less energy loss at the time of production than conventional phenolic binders, has excellent rigidity and flexible texture, and is suitable for housing and buildings. It is possible to provide an inorganic fiber heat-absorbing and sound-absorbing material suitable for construction.
以下に、本発明を実施例によって説明する。本発明は下記の実施例に制限されるものではない。なお、以下の説明において、部及び％は、質量基準を表す。 Hereinafter, the present invention will be described by way of examples. The present invention is not limited to the following examples. In the following description, parts and% represent mass standards.
（実施例１）
重合度が３００で、ケン化度が８８%である日本酢ビ・ポバール社製のポリビニルアルコール系樹脂「ＪＬ−０５Ｅ」の水溶液を固形分換算で９２．５部と、架橋剤として五協産業社製マレイン酸系共重合物「ガントレンツＡＮ‐１１９」の水溶液を固形分換算で７．５部と、柔軟剤として出光興産社製の重質オイルエマルション「ダフニープロソルブルＰＦ」を固形分換算で１５部及び信越化学社製シリコーンオイルエマルション「Ｐｏｌｏｎ ＭＲ」を固形分換算で５部とを混合し、撹拌後、水溶液の濃度が４．０%になるように、水で調整して、実施例１の無機繊維用水溶性バインダーを得た。
Example 1
92.5 parts of an aqueous solution of polyvinyl alcohol resin “JL-05E” manufactured by Nippon Vineyard-Poval Co., which has a polymerization degree of 300 and a saponification degree of 88%, in terms of solid content, and as a cross-linking agent 7.5 parts by weight of an aqueous solution of maleic acid-based copolymer “Gantrenz AN-119” manufactured by the company and a heavy oil emulsion “Daffney Prosolvable PF” manufactured by Idemitsu Kosan Co., Ltd. as a softener. 15 parts and Shin-Etsu Chemical's silicone oil emulsion “Polon MR” were mixed with 5 parts in terms of solid content, and after stirring, adjusted with water so that the concentration of the aqueous solution was 4.0%. The water-soluble binder for inorganic fibers of Example 1 was obtained.
（実施例２）
重合度が３００で、ケン化度が８８%である日本酢ビ・ポバール社製のポリビニルアルコール系樹脂「ＪＬ−０５Ｅ」の水溶液を固形分換算で９６部と、架橋剤としてホウ砂の４％水溶液を固形分換算で４部と、柔軟剤として出光興産社製の重質オイルエマルション「ダフニープロソルブルＰＦ」を固形分換算で１５部及び信越化学社製シリコーンオイルエマルション「Ｐｏｌｏｎ ＭＲ」を固形分換算で５部とを混合し、撹拌後、水溶液の濃度が４．０%になるように、水で調整して、実施例２の無機繊維用水溶性バインダーを得た。
(Example 2)
96 parts of an aqueous solution of polyvinyl alcohol-based resin “JL-05E” manufactured by Nihon Ventures and Poval with a polymerization degree of 300 and a saponification degree of 88%, and 4% of borax as a cross-linking agent 4 parts of aqueous solution in terms of solid content, 15 parts of heavy oil emulsion “Daffney Prosolvable PF” made by Idemitsu Kosan Co., Ltd. as a softening agent, and solid part of silicone oil emulsion “Polon MR” made by Shin-Etsu Chemical Co., Ltd. 5 parts in terms of minutes were mixed, and after stirring, the mixture was adjusted with water so that the concentration of the aqueous solution was 4.0%, to obtain a water-soluble binder for inorganic fibers of Example 2.
（比較例１）
ＤＩＣ製無機繊維用水溶性フェノール系樹脂「フェノライト」の水溶液を固形分換算で１００部と、柔軟剤として、出光興産社製の重質オイルエマルション「ダフニープロソルブルＰＦ」を固形分換算で１５部及び信越化学社製シリコーンオイルエマルション「Ｐｏｌｏｎ ＭＲ」を固形分換算で５部とを混合し、撹拌後、水溶液の濃度が４．０%になるように、水で調整して、比較例１の無機繊維用水溶性バインダーを得た。尚、使用した水溶性フェノール樹脂は、すでに架橋剤（ホルムアルデヒド）が混合されたものを使用している為、新たに架橋剤は添加していない。
(Comparative Example 1)
100 parts of aqueous solution of water soluble phenolic resin “Phenolite” for inorganic fiber made by DIC in terms of solid content and 15% of heavy oil emulsion “Daffney Prosolvable PF” made by Idemitsu Kosan Co., Ltd. as softener. Comparative Example 1 was prepared by mixing 5 parts with a silicone oil emulsion “Polon MR” manufactured by Shin-Etsu Chemical Co., Ltd. The water-soluble binder for inorganic fibers was obtained. In addition, since the used water-soluble phenol resin already uses what mixed the crosslinking agent (formaldehyde), the crosslinking agent is not newly added.
（比較例２）
ポリアクリル酸を主成分とした三洋化成製無機繊維用水溶性アクリル樹脂「グラスパール」の水溶液を固形分換算で１００部と、柔軟剤として、出光興産社製の重質オイルエマルション「ダフニープロソルブルＰＦ」を固形分換算で１５部及び信越化学社製シリコーンオイルエマルション「Ｐｏｌｏｎ ＭＲ」を固形分換算で５部とを混合し、撹拌後、水溶液の濃度が４．０%になるように、水で調整して、比較例２の無機繊維用水溶性バインダーを得た。尚、使用した水溶性アクリル酸重合物は、すでに架橋剤が添加されたものを使用している為、新たに架橋剤は添加していない。
(Comparative Example 2)
100 parts of water-soluble acrylic resin “Glasspearl” for Sanyo Kasei's inorganic fiber based on polyacrylic acid as a solid component, and as a softener, a heavy oil emulsion made by Idemitsu Kosan Co., Ltd. PF ”is mixed with 15 parts in terms of solid content and silicone oil emulsion“ Polon MR ”manufactured by Shin-Etsu Chemical Co., Ltd. with 5 parts in terms of solid content. After stirring, water is added so that the concentration of the aqueous solution becomes 4.0%. Thus, a water-soluble binder for inorganic fibers of Comparative Example 2 was obtained. In addition, since the used water-soluble acrylic acid polymer used the thing to which the crosslinking agent was already added, the crosslinking agent is not newly added.
実施例１及び２、比較例１及び２で得られた無機繊維用水溶性バインダーを用いて、下記に記す方法にて評価を実施した。 Using the water-soluble binder for inorganic fibers obtained in Examples 1 and 2 and Comparative Examples 1 and 2, evaluation was carried out by the method described below.
（バインダー硬化温度の評価）
実施例１及び２、比較例１及び２で得られた無機繊維用水溶性バインダーを、各温度に設定した熱板上に１ミリリットルを滴下し、熱板上で硬化するまでの時間を測定した。測定結果は、表-１にて記し、硬化時間と加熱温度の関係図として図１に示した。また、図１より水分の蒸発時間を除いた樹脂成分の硬化時間と加熱温度の関係図を図２に示した。
(Evaluation of binder curing temperature)
1 ml of the water-soluble binder for inorganic fibers obtained in Examples 1 and 2 and Comparative Examples 1 and 2 was dropped on a hot plate set at each temperature, and the time until curing on the hot plate was measured. The measurement results are shown in Table 1, and are shown in FIG. 1 as a relationship diagram between the curing time and the heating temperature. FIG. 2 shows a relationship between the curing time of the resin component excluding the water evaporation time from FIG. 1 and the heating temperature.
上記結果より、実施例１及び２は、比較例１及び２と比べ、かなり低い温度で硬化する事が確認出来た。尚、実施例１及び２において、参考のために２４０℃の加熱温度までの試験を行ったが、本発明の無機繊維断熱吸音材は、１００〜２００℃の加熱温度で硬化させるものである。硬化時間を一定にした場合、実施例１及び２は、比較例１及び２より、７０℃低い温度で硬化できる。
尚、加熱温度が１１０℃及び１３０℃の場合、比較例１及び２においては、樹脂が硬化しなかった。
From the above results, it was confirmed that Examples 1 and 2 were cured at a considerably lower temperature than Comparative Examples 1 and 2. In Examples 1 and 2, a test up to a heating temperature of 240 ° C. was performed for reference. The inorganic fiber heat-absorbing sound-absorbing material of the present invention is cured at a heating temperature of 100 to 200 ° C. When the curing time is constant, Examples 1 and 2 can be cured at a temperature lower by 70 ° C. than Comparative Examples 1 and 2.
In addition, when heating temperature was 110 degreeC and 130 degreeC, in Comparative Example 1 and 2, resin did not harden | cure.
（加熱エネルギー試算）
実施例１及び２、比較例１及び２で得られた無機繊維用水溶性バインダーを、遠心法により繊維化したグラスウールに５．０％の付着量になる様にスプレー装置にて塗布し、無機繊維堆積装置内で吸引しながら有孔コンベア上に堆積させ、無機繊維中間体を得た。得られた無機繊維中間体をそれぞれの樹脂特性に適した乾燥温度（実施例１及び２：１８０℃，比較例１：２４０℃，比較例２：２６０℃）にて、５分間の加熱処理を実施し、各温度に加熱するのに必要な時間当たりの加熱エネルギー量を試算し、表２に記した。尚、エネルギー改善率は、従来技術の代表例たるフェノール樹脂（比較例１）を基準とし、フェノール樹脂を用いた場合に比較してどの程度エネルギーが改善されるかを示した。
(Estimation of heating energy)
The inorganic fiber water-soluble binder obtained in Examples 1 and 2 and Comparative Examples 1 and 2 was applied to a glass wool fiberized by a centrifugal method with a spray device so as to have an adhesion amount of 5.0%. The inorganic fiber intermediate was obtained by depositing on a perforated conveyor while sucking in a deposition apparatus. The obtained inorganic fiber intermediate is subjected to a heat treatment for 5 minutes at a drying temperature (Examples 1 and 2: 180 ° C., comparative example 1: 240 ° C., comparative example 2: 260 ° C.) suitable for each resin characteristic. The amount of heating energy per hour required for heating to each temperature was calculated and listed in Table 2. In addition, the energy improvement rate showed how much energy was improved compared with the case where a phenol resin was used on the basis of the phenol resin (comparative example 1) which is a typical example of a prior art.
上記より、ポリビニルアルコール系樹脂を使用した実施例１及び２は、比較例１のフェノール系樹脂を使用した場合に比べ、樹脂硬化に伴う、乾燥機後半部で６０℃から９０℃低い温度で硬化させることができた。そして、上表記載の温度に加熱する為に必要な加熱エネルギーも７％から９％削減する事ができた。 From the above, Examples 1 and 2 using a polyvinyl alcohol-based resin were cured at a lower temperature of 60 ° C. to 90 ° C. in the latter half of the dryer, as compared with the case of using the phenolic resin of Comparative Example 1, in the latter half of the dryer. I was able to. The heating energy required for heating to the temperatures shown in the above table could also be reduced by 7% to 9%.
（柔軟性及び剛性の評価）
前項で加熱処理を行い、密度１６ｋｇ／ｍ３、厚さ１００ｍｍ、バインダー付着率５．０％の無機繊維断熱吸音材を得た。得られたそれぞれの無機繊維断熱吸音材を、ＳＨＩＭＡＤＺＵ社製万能試験機「ＡＧ−ＩＳ」を用い、元厚さに対し、１０％まで圧縮した時の反発力（低圧強度）と、５０％まで圧縮した時の反発力（高圧強度）を測定し、比較した。測定結果は下記表に示した。
尚、低圧強度は、人間が無機繊維断熱吸音材を把持した時の感触に関するものである。２００Ｎ／ｍ２以下だと、人間が把持した場合に、感触が良いと感じる。２５０Ｎ／ｍ２以上の場合、人間が把持した場合に皮膚に刺さる様な悪い触感を感じる。
高圧強度は、無機繊維断熱吸音材の強度に関するものである。１０００Ｎ／ｍ２以下の場合、柔らか過ぎ、切断等の加工や施工がし難くなる。また、１０００Ｎ／ｍ２以上の場合、切断等の加工や施工がし易いものと言える。
(Evaluation of flexibility and rigidity)
Heat treatment was performed in the previous section to obtain an inorganic fiber heat insulating sound absorbing material having a density of 16 kg / m 3 , a thickness of 100 mm, and a binder adhesion rate of 5.0%. Rebound force (low pressure strength) when compressing each inorganic fiber heat-absorbing and sound-absorbing material to 10% of original thickness using SHIMADZU universal tester “AG-IS”, up to 50% The repulsive force (high pressure strength) when compressed was measured and compared. The measurement results are shown in the following table.
The low-pressure strength relates to a feeling when a human grips the inorganic fiber heat insulating material. When it is 200 N / m 2 or less, it feels good when a human grips it. In the case of 250 N / m 2 or more, a bad tactile sensation such as piercing the skin is felt when a human grips.
The high-pressure strength relates to the strength of the inorganic fiber heat insulating sound absorbing material. When it is 1000 N / m 2 or less, it is too soft, and it becomes difficult to process and construct such as cutting. Moreover, when it is 1000 N / m < 2 > or more, it can be said that it is easy to process and construct such as cutting.
上記結果より、実施例１及び２は、比較例１と比べ、人の触感に関わる低圧強度が低く、無機繊維断熱吸音材の剛性に関わる高圧強度が高い結果となった。又、比較例２は、低圧強度及び高圧強度共に低く、柔らかい風合いであるが、剛性も弱い結果となった。実施例１及び２によれば、柔軟剤の存在により、無機繊維断熱吸音材の剛性を維持したまま、適度な柔軟性を付与する事ができた。比較例１の場合、硬化温度の高いフェノール樹脂を使用したため、硬化温度を２４０℃とする必要があり、このため、柔軟剤が熱分解したためと思われる。比較例２は、硬化温度の高いアクリル樹脂を使用した為、柔軟剤の熱分解は起こったが、樹脂硬化物自体の強度が弱く、剛性も劣る結果となったと思われる。これにより、実施例１及び２は、比較例１及び２より、柔軟な風合いを有し、且つ、優れた剛性を有する事が確認出来た。
From the above results, Examples 1 and 2 had a low low-pressure strength related to human tactile sensation and a high high-pressure strength related to the stiffness of the inorganic fiber heat-absorbing sound-absorbing material, as compared with Comparative Example 1. In Comparative Example 2, both the low pressure strength and the high pressure strength were low and the texture was soft, but the rigidity was also weak. According to Examples 1 and 2, due to the presence of the softening agent, moderate flexibility could be imparted while maintaining the rigidity of the inorganic fiber heat-absorbing sound absorbing material. In the case of Comparative Example 1, since a phenol resin having a high curing temperature was used, it was necessary to set the curing temperature to 240 ° C., and it is considered that the softening agent was thermally decomposed. In Comparative Example 2, since the acrylic resin having a high curing temperature was used, the softening agent was thermally decomposed. However, it seems that the resin cured product itself was weak in strength and inferior in rigidity. Thereby, it was confirmed that Examples 1 and 2 had a softer texture and superior rigidity than Comparative Examples 1 and 2.
本発明の無機繊維断熱吸音材は、従来のフェノール系バインダーを使用した無機繊維断熱吸音材と比較し、製造時のエネルギー消費が少なく、優れた剛性と柔軟な風合いを有し、住宅や建物への好適に使用できる。 The inorganic fiber heat-absorbing sound-absorbing material of the present invention has less energy consumption during production compared to conventional inorganic fiber heat-absorbing sound-absorbing materials using phenolic binders, has excellent rigidity and flexible texture, and is suitable for housing and buildings. Can be suitably used.
Claims (5)
前記熱可塑性樹脂が、ポリビニルアルコール系樹脂であり、
前記柔軟剤は、（ａ）重質オイル、（ｂ）シリコーンオイル、又は、（ｃ）その混合物の水分散体であることを特徴とする、無機繊維用水溶性バインダー。 A water-soluble binder for inorganic fibers , which contains a water-soluble polymer mainly composed of a thermoplastic resin, a crosslinking agent, and a softening agent and can be cured at a heating temperature of 100 to 200 ° C. ,
The thermoplastic resin is a polyvinyl alcohol resin,
The water- soluble binder for inorganic fibers , wherein the softening agent is an aqueous dispersion of (a) heavy oil, (b) silicone oil, or (c) a mixture thereof .
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